Livro: Technology Innovation in Underground Construction 1. Introduction 1.1 Motivation 1.2 Problems 1.3 Vision 1.3.1 Design 1.3.2 Processes 1.3.3 Equipment and materials 1.3.4 Maintenance an repair 1.4 Contents of the book 2. UCIS Underground construction information system 2.1 Introduction 2.2 UCIS Underground construction information system 2.2.1 Objectives 2.2.2 Architecture 2.2.3 Design and development 2.2.4 Data model 2.2.5 3D ground model 2.3 Introduction 2.4 Contribution to the overall project 2.5 Workflow 2.6 Geometrical data: software implementation 2.7 Geological & geomechanical attributes: classification 2.8 Geological & geotechnical database 2.9 Data link geometrical data geological/ geotechnical objects 2.10 Subsurface models 2.10.1 UCIS Applications 2.11 KRONOS tunnel information system 2.12 KRONOS-WEB monitoring data reporting and alarming system 2.13 Decision support system for cyclic tunnelling 2.14 Web-based information system on underground construction projects 2.15 Virtual reality visualisation system 2.16 Summary 3. Computer-support for the design of underground structures 3.1 Introduction 3.2 State-of-the-art in tunnel design 3.3 The applied design concept 3.3.1 Design method 3.3.2 Analysis of the possible degree of automation 3.3.3 Automation concept 3.4 Rule base for tunnel pre-design 3.4.1 Determination of the ground behaviour 3.4.2 Determination of suitable excavation methods and support measures 3.5 Key input parameters 3.6 Support classes 3.7 Energy classes 3.8 Excavation methods 3.9 Refinement for shield tunneling 3.9.1 General workflow embedded in the rule base 3.9.2 Determination of time and costs 3.10 Integrated optimization platform for underground construction 3.10.1 Realization/implementation 3.11 Graphical user interface 3.12 3D-Ground model 3.13 Rule base 3.14 Numerical simulation software 3.14.1 Background information and software technology 3.15 Summary 4. A virtual reality visualisation system for underground construction 4.1 Introduction 4.1.1 Virtual reality 4.1.2 Augmented reality 4.1.3 Mixed reality 4.1.4 Capacity of today s VR-, AR- and MR-systems 4.2 A Virtual reality visualisation system for underground construction 4.2.1 Objective 4.2.2 Input data 4.2.3 VR software 4.2.4 VR hardware 4.2.5 Application example 4.3 Summary 4.4 Outlook, augmented reality in tunnelling 5. From laboratory, geological and TBM data to input parameters for simulation models 5.1 Introduction 5.2 A hierarchical, relational and web-driven Rock Mechanics Database 5.2.1 Introduction
5.2.2 Test data reduction methodology 5.2.3 A failure criterion for rocks 5.2.4 Example calibration of lab test rock parameters to model parameters of the HMC constitutive model (Level-B of analysis) 5.2.5 Structure of the rock mechanics database 5.3 Geometrical and geostatistical discretization of geological solids 5.3.1 Introduction 5.3.2 Solid modeling 5.3.3 Geostatistical modeling 5.4 A special upscaling theory of rock mass parameters 5.4.1 Introduction 5.4.2 A special upscaling theory for rock masses 5.4.3 Illustrative upscaling example 5.5 Back-analysis of tbm logged data 5.5.1 Introduction 5.5.2 Basic relationships 5.5.3 An example of backward analysis 5.6 Conclusions 6. Process-oriented numerical simulation of mechanised tunnelling 6.1 Introduction 6.1.1 Requirements for computational models for mechanised tunnel construction 6.1.2 Novel computational framework for process-oriented simulations in mechanised tunnelling as part of an integrated decision support system 6.2 Three-phase model for partially saturated soil 6.2.1 Theory of porous media 6.2.2 Governing balance equations 6.2.3 Constitutive relations for hydraulic behaviour 6.2.4 Stress-strain behaviour of soil skeleton 6.3 Finite element formulation of the multiphase model for soft soils 6.3.1 Spatial and temporal discretization 6.3.2 Object-oriented implementation 6.4 Selection of soil models and parameters 6.4.1 Saturated soil model 6.4.2 Unsaturated soil model 6.4.3 Cemented soil model 6.4.4 Double hardening soil model 6.5 Verification of the three-phase model for soft soils 6.5.1 Consolidation test 6.5.2 Drying test 6.6 Components of the finite element model for mechanised tunnelling 6.6.1 Heading face support 6.6.2 Frictional contact between TBM and soil 6.6.3 Tail void grouting 6.6.4 Shield machine, hydraulic jacks, lining and backup trailer 6.7 Model generation and simulation procedure 6.7.1 Automatic model generation 6.7.2 Mesh adaption for TBM advance and steering of shield machine 6.7.3 Interface to IOPT 6.7.4 Parallelisation concept 6.8 Sensitivity analysis and parameter identification 6.8.1 Numerical approximation of sensitivity terms 6.8.2 Analytical sensitivities derived by the direct differentiation method 6.8.3 Adjoint method for deriving analytical sensitivities 6.8.4 Implementation of analytical sensitivity methods 6.8.5 Optimisation of process parameters 6.8.6 Inverse analyses for estimation of unknown parameters 6.8.7 Current state and outlook for further developments in sensitivity analyses 6.9 Selected applications of the simulation model for mechanised tunnelling 6.9.1 Numerical simulation of compressed air support 6.9.2 Numerical simulation of changing pressure conditions at the heading face 6.9.3 Numerical simulation of the Mas Blau section of L9 of Metro Barcelona 6.10 Conclusions 7. Computer simulation of conventional construction 7.1 Introduction 7.2 A new simulation paradigm 7.3 Preprocessor 7.4 The boundary element method 7.4.1 Sequential excavation 7.5 Example sequential tunnel excavation 7.5.1 Non-linear material behavior 7.6 Non-linear BEM 7.7 The non-linear solution algorithm 7.8 Hierarchical constitutive model 7.9 Example 7.9.1 Heterogeneous ground and ground improvement methods 7.10 Introduction 7.11 Consideration of geological conditions 7.12 Pipe roofs 7.13 Examples 7.13.1 Rock bolts 7.14 Introduction 7.15 Fully grouted rock bolts 7.16 Discrete anchored bolts 7.17 Examples 7.17.1 Shotcrete and steel arches 7.18 Introduction 7.19 Shotcrete as an assembly of shell finite elements 7.20 Steel arches as an assembly of beam finite elements
7.21 Optimization of code and adaptation to special hardware 7.21.1 Computational complexity 7.21.2 Iterative solvers 7.21.3 Fast methods 7.21.4 Modern hardware parallelization 7.22 Practical application 7.22.1 The koralm tunnel 8. Optical fiber sensing cable for underground settlement monitoring during tunneling 8.1 Introduction 8.1.1 Tunnel construction with tunnel boring machines 8.1.2 Risk associated to tunneling in urban areas 8.1.3 State of the art 8.1.4 Research frame 8.1.5 Settlement to be measured 8.1.6 Developed solutions 8.2 Sensors based on deformation of optical fibres 8.2.1 General principles 8.2.2 Brillouin technology 8.2.3 Fiber embedded at the periphery of a cable or a tube 8.2.4 Cable environment 8.2.5 Development of an industrial process 8.3 Sensing element 8.4 15 mm diameter cable 8.5 150 mm diameter cable 8.6 Sensors based on slope measurement 8.7 Sensor validation 8.7.1 Geometric validation in open air 8.8 Bench test 8.9 Optical fiber validation 8.10 TBMSET validation 8.10.1 Geometric validation in buried material cairo tests 8.11 Presentation of cairo project 8.12 Test area 8.13 Settlement gauges network 8.14 Installation of the test area 8.15 On site data acquisition from sensing elements 8.16 Job site data 8.17 Settlement gauges 8.18 Validation of pipe behavior inside the ground 8.19 Impact of grout injection on the settlement 8.20 Optical fiber results 8.21 TBMSET results 8.22 Conclusion 9. Tunnel seismic exploration and its validation based on data from TBM control and observed geology 9.1 Introduction 9.2 Seismic exploration during tunneling 9.2.1 Challenges 9.2.2 Finite-difference simulations of seismic data 9.3 Description of the discrete model 9.4 Modeling results 9.4.1 Short outline of seismic data processing 9.5 Pre-processing 9.6 Migration and velocity analysis 9.7 Use of TBM data and geology for seismic data validation 9.8 Conclusions 10. Advances in the steering of Tunnel Boring Machines 10.1 Introduction 10.1.1 Motivation 10.1.2 Solution concept 10.2 Analysis of relevant steering parameters 10.2.1 TBM control and monitoring systems state of the art 10.3 Systems for subsidence monitoring 10.4 Monitoring systems for geodetic survey of the machine position and orientation 10.5 Steering system for the control parameters of the tunnelling machine 10.5.1 Induced surface deformations and control parameters during shield drive 10.6 Subsidence in front of the cutter head (advanced subsidence) 10.7 Subsidence in the area of the shield 10.8 Subsidence associated with annular gap grouting 10.9 Subsidence after hardening of the annular gap mortar (subsequent subsidence) 10.9.1 Expert rules for subsidence control 10.10 Steering system 10.10.1 Requirements 10.10.2 Solution concept and system architecture 10.10.3 Fuzzy logic expert system and reasoning 10.11 Rules 10.12 Fuzzy logic data evaluation 10.12.1 Software system developed 10.12.2 verification and validation 10.13 Incident management system 10.13.1 General 10.13.2 Causes for incidents 10.14 Geology and hydrology 10.15 Shield machine 10.16 Operation errors 10.16.1 Development of the incident catalogue 10.16.2 Description of the incident management system 10.16.3 Showcase example in detail 10.16.4 Automated detection of incidents 10.17 Conclusion 11. Real-time geological mapping of the front face 11.1 Introduction 11.2 State of the art
11.3 Technological solution 11.3.1 Objectives 11.3.2 Specifications 11.3.3 Technological choices 11.4 Disc cutter and housing 11.5 Overall description 11.6 Monitored parameters 11.7 Disc cutter modeling 11.8 Mobydic monitoring 11.9 Applications 11.9.1 Lock ma shau tunnel 11.9.2 A41 11.10 Conclusion 12. Reducing the environmental impact of tunnel boring (OSCAR) 12.1 Introduction 12.2 State of the art 12.2.1 Historical context 12.2.2 Tunnel construction with tunnel boring machine 12.2.3 Soil conditioning for EPB machine 12.3 Research project description 12.3.1 Objective 12.3.2 The overall objective of these tests isto define the specific additive properties versus specific situations, e.g. soil, confinement pressure, soil permeability, and to develop adapted foams. A computer program has been written for the right selection the foam dosage. Selected tests 12.4 Oscar reactor 12.4.1 OSCAR general view 12.4.2 The reactor 12.4.3 Screw conveyor 12.4.4 Baroïd water loss filter (Garcia, IFP) 12.4.5 Direct output 12.4.6 Foam production (Fig. 11) 12.5 Test results 12.5.1 Soil 12.6 Soil types 12.7 Clay 12.8 Silt 12.9 Sand 12.10 Mixed soil 12.11 Soil with gypsum content 12.12 Soil conditioning 12.12.1 Additives 12.13 Surfactants 12.14 Foam design rules 12.15 Specifications of foams 12.16 Polymers 12.17 Other additives 12.18 Specification of foams 12.19 Input required and calculation of foam parameters 12.20 Atmospheric tests 12.21 Hyperbaric Tests 12.22 Foam dosage computation 12.23 Proposed draft standard 12.23.1 Ground sampling 12.23.2 Cutter head sealant 12.23.3 Soil conditioning test 12.24 Step 1: Atmospheric tests 12.25 Step 2: Atmospheric tests 12.26 Step 3: Pressurized tests 12.27 Conclusion 13. Safety assessment during construction of shotcrete tunnel shells using micromechanical material models 13.1 Introduction 13.2 Modeling cementitious materials in the framework of continuum micromechanics 13.2.1 Fundamentals of micromechanics Representative volume element (RVE) 13.2.2 Micromechanical representation of cementitious materials 13.2.3 Elasticity and strength of cementitious materials 13.3 Morphological representation of hydration products in cement paste 13.4 Strength of cement paste 13.5 Strength of shotcrete 13.6 Experimental validation of micromechanics-based material models 13.6.1 Mixture-dependent shotcrete composition 13.6.2 Experimental validation on cement paste level 13.6.3 Experimental validation on shotcrete level 13.7 Micromechanics-based characterization of shotcrete: Influence of water-cement and aggregate-cement ratios on elasticity and strength evolutions 13.8 Continuum micromechanics-based safety assessment of natm tunnel shells 13.8.1 Water-cement ratio-dependence of structural safety 13.8.2 Aggregate-cement ratio-dependence of structural safety 13.9 Conclusions 14. Observed segment behaviour during tunnel advance 14.1 Introduction 14.2 Organization of the chapter 14.3 Forces on the EPB machine 14.3.1 Excavation mode 14.3.2 Ring mounting mode 14.4 Eccentricity of the Jack s total thrust 14.5 Backfill mortar injection pressures 14.6 Study of several cases 14.6.1 Collection and treatment of data 14.6.2 Geological considerations
14.6.3 Comparison between theoretical and EPB machine registered thrusts 14.6.4 Registered eccentricities 14.6.5 Tests to measure the pressure on the segments using pressure sensors 14.7 Conclusions 14.7.1 Definition of the forces acting on the EPB machine. 14.7.2 Effects of the eccentricity of the resultant of thrusting forces 14.7.3 Distribution of the backfill mortar pressures 15. Optimizing rock cutting through computer simulation 15.1 Introduction 15.2 Tool rock interaction 15.3 Wear of rock cutting tools 15.4 Thermomechanical model of rock cutting 15.5 Wear model 15.6 Determination of rock model parameters 15.7 Simulation of rock cutting laboratory test 15.8 Simulation of rock cutting with wear evaluation 15.9 3D simulation of the laboratory test of rock cutting 15.10 Simulation of the linear cutting test 15.11 Conclusions 16. Innovative roadheader technology for safe and economic tunnelling 16.1 Roadheaders state of the art 16.1.1 Tunneling with roadheaders 16.1.2 The principle of roadheader operation 16.1.3 Roadheader components 16.2 Overview 16.3 Cutter head, picks 16.3.1 Roadheader application 16.3.2 Roadheader selection 16.4 Rock parameters 16.5 Profile size mode of application 16.6 One-step face excavation 16.7 Multi-step excavation of larger sections 16.8 Application in difficult ground conditions 16.8.1 Application example: Mont Cenis Tunnel/France Italy 16.8.2 Application example: Metro Montreal Project, Lot C 04/Canada 16.9 The new roadheader generation features and benefits 16.9.1 New technology 16.9.2 Integrated guidance system 16.10 Introduction 16.11 System principle 16.11.1 Improved sandvik cutting technology 16.12 Introduction 16.13 Pick-rock interaction 16.14 Numerical simulation 16.15 Outlook 17. Tube-à-manchette installation using horizontal directional drilling for soil grouting 17.1 Introduction 17.2 development of an articulated double packer 17.3 development of a blocking system for the sealing grout 17.4 design of the test 17.5 test development 17.5.1 Phase 1: Initial works 17.5.2 Phase 2: Horizontal directional drilling 17.5.3 Phase 3: Steel casing installation 17.5.4 Phase 4: Steel casing extraction 17.5.5 Phase 5: Injection of the grout bag 17.5.6 Phase 6: Annular sheath grouting 17.5.7 Phase 8: Ground injection 17.6 Summary 18. TBM technology for large to very large tunnel profiles 18.1 Introduction 18.2 Two mixshields for the railway tunnel access route to the brenner base tunnel 18.3 Two double shielded hard rock TBMs for the Brisbane North South Bypass Tunnel (NSBT) 18.4 Trend of very large diameter tunnel profiles 18.4.1 Largest earth pressure balance shield (Ø15.2M) used for the M30 road tunnel project in Madrid 18.4.2 Largest mixshield (Ø15.4 m) used for the Changjiang under river tunnel project in Shanghai 18.5 Tunconstruct activities 19. Real-time monitoring of the shotcreting process 19.1 Introduction 19.2 Monitoring the shotcreting process 19.2.1 Pumping variables 19.2.2 Spraying variables 19.3 Final remarks 20. Environmentally friendly, customised sprayed concrete 20.1 Introduction 20.2 Performance-based approach 20.3 Indicators chosen and their meanings 20.3.1 Constituent materials and mix proportions 20.3.2 Full scale sample preparation and tests conducted 20.4 Advantages of the approach: selected results 20.5 Final remarks and conclusions 20.6 Abbreviations 21. Innovations in shotcrete mixes 21.1 Introduction 21.2 Innovations 21.2.1 New components materials PB criterion 21.2.2 New special superplasticizer and nozzle accelerator 21.3 Special superplasticizer 21.4 Nozzle accelerator
21.4.1 New SM Automation of shotcrete machine 21.4.2 New admixture dosing unit 21.5 Shotcrete simplified mix design rules program 21.5.1 MDR (Mix Design Rules) 21.5.2 SMD (Shotcrete Mix design) 21.5.3 RER Validation factor 24.3 Rock mass characterization with the stackable logging tools 24.3.1 Field tests 24.3.2 Rock quality estimation and borehole geophysical logging 24.4 Summary and conclusions 21.6 Summary 22. High performance and ultra high performance concrete segments development and testing 22.1 Introduction 22.2 Development and laboratory testing 22.2.1 Basic recipe development 22.2.2 Derivation of design parameters and re-calculation 22.2.3 Comparative calculations 22.2.4 Checking of fire resistant behavior 22.2.5 Testing of industrial segment production 22.3 Real scale tests 22.3.1 General 22.3.2 Segment load bearing test 22.4 General 22.5 Test stand (Fig. 22.8) 22.6 Measurement 22.7 Conducting the segment load bearing test 22.7.1 Diaphragm load test 22.8 General 22.9 Test stand (Fig. 22.12) 22.10 Measurement 22.11 Conducting the diaphragm load test 22.11.1 Torsional rigidity test 22.12 General 22.13 Test stand (Fig. 22.14) 22.14 Measurement 22.15 Conducting the torsional rigidity test 22.16 First test results 22.17 Summary 23. Robotic tunnel inspection and repair 23.1 Introduction 23.2 Dragarita robot for fast inspection 23.3 IRIS: Integrated robotic inspection and maintenance system 23.3.1 Maintenance operations 23.3.2 Integrated process automation 23.3.3 Laboratory and field tests 23.4 Conclusions 24. An innovative geotechnical characterization method for deep exploration 24.1 Introduction 24.2 Background