Bernhard Maidl, Leonhard Schmid, Willy Ritz, Martin Herrenknecht Hardrock Tunnel Boring Machines In co-operation with Gerhard Wehrmeyer and Marcus Derbort -=rnst & Sohn '-A Wiley Company
Contents 1 Historical Development and Future Challenges 2 Basic Principles and Definitions 15 21 Basic Principles and Construction 16 211 Boring System 16 212 Thrust and Clamping System 17 213 Muck Removal System 18 214 Support System 18 22 Definitions and Terms 20 221 Tunnel Boring Machines with Full-Face Excavation 20 2211 Gripper TBM 20 2212 Shielded TBM 22 222 Tunnel Boring Machines for Partial Excavation 23 3 Boring Operation 25 31 The Boring Process 25 32 The Cutter Head 26 321 Shape ofthe Cutter Head 27 322 Clearing the Muck in the Excavation Area 29 323 Cutter Head Construction and Soil Consolidation 31 33 Cutting Tools 32 331 General 32 332 Working Method of Cutter Discs 33 333 Cutter Spacing 36 334 Penetration 38 335 Wear 41 336 Wear and Water 48 337 Cutter Housing 49 34 The Main Drive 50 341 Types ofmain Drive 50 342 Main Bearing 53 35 Advance Rate 53 36 Special Types 55 361 Reamer TBMs 56 362 Bouygues System 57 363 Mobile Miner (Robbins) 58 364 Back-Cutting Technology 58 3641 Mini-Fullfacer (Atlas Copco) 58 3642 Continuous Miner 60 365 Shaft Sinking 61 3651 Raise Boring 62
VIII Contents 3652 Blind Drilling 64 3653 Combinations 65 4 Thrust 67 41 General 67 42 Advance with Gripper Clamping 67 43 Advance with a Shield TBM 72 5 Material Transport 75 51 Material Transport at the Machine 75 52 Material Transport Through the Tunnel 77 521 Rail Transport 77 5211 Diesel or Electric Operation 79 5212 Muck Cars 79 5213 Loading in the Tunnel 80 5214 Train Timetable 80 5215 Tunnel Track 81 522 Trackless Operation 81 5221 Transport Vehicles 82 5222 Haul Road 82 5223 Loading 82 523 Conveyor Transport 84 5231 Conveyor Storage 85 5232 Conveyor Belt Extension and Belt Operation 85 5233 Advantages of Conveyor Transport and Innovation Potential 87 6 Backup Equipment 89 61 Backup Concept 89 62 Design Specifications 93 7 Ventilation, Dust Removal, Working Safety,Vibration 99 71 Ventilation 99 711 Danger 99 712 Ventilation Schemes, Ventilation Systems 99 72 Dust Removal 100 73 Occupational Safety and Safety P1anning for TBM Operation 103 731 General 103 732 International Guidelines and National Regulations 104 7321 International Guidelines 104 7322 National Regulations 104 733 Integrated Safety Plan 106 7331 The Safety Plan in the Environment ofmanagement Plans 106 7332 Safety Aims 107 7333 Description ofdangers and Risk Analyses 107
Contents IX 7334 Action Plan 109 734 TBM Details and Specifics Regarding Natural Gas Danger and Rock Support 110 7341 Natural Gas Danger 110 7342 Rock Support 111 74 Vibration 111 8 Additional Equipment 115 81 Investigation and Improvement ofthe Geological Conditions 115 82 Equipment for Rock Support 117 821 Anchor Drills 117 822 Steel Ring Equipment 118 823 Mesh Installation Equipment 118 824 Innovation Aims 119 83 TBM Steering 119 831 Steering the Gripper TBM with Single Bracing 119 832 Steering the Gripper TBM with X-Type Clamping 122 833 Steering a Single Shield TBM 122 834 Steering a Double Shield TBM 125 84 Surveying 126 841 Surveying the Position ofthe Tunnel Boring Machine 127 842 Forward Calculation ofthe TBM Route 127 9 Tunnel Support 129 91 General 129 92 Support Systems and Advance Rates 130 93 Systematic Support at the Machine 133 931 Steel Arch Support 133 932 Liner Plates 136 933 Segments 137 9331 lnvert Segments 137 9332 Segmental Lining 137 94 Shotcrete Support 142 941 Shotcrete Support at the Machine 142 942 Shotcrete Support in the Backup Area 143 95 Localised Support 144 951 Anchors and Mesh 144 952 Arch Support 145 96 Stabilisation Ahead ofthe Cutter Head 146 10 Gripper TBM and Shield Machine Combinations 149 101 Roof Shields 149 102 Roof Shield and Side Steering Shoes and Cutter Head Shields 152 103 Walking Blade Gripper TBM 153
x 104 1041 1042 10421 10422 105 1051 1052 1053 10531 10532 106 1061 1062 107 1071 1072 1073 10731 10732 10733 10734 10735 108 1081 1082 10821 10822 11 111 112 1121 1122 1123 113 1131 1132 1133 1134 Contents Full-Face Shield Machines ISS Developments 155 Special Characteristics 156 Cutter Head and Shie1d 157 Thrust Ring 157 Double Shields 159 Developments 159 Functional Principle 159 Special Cases 160 Shield and Bentonite Lubrication 160 Telescopic Shield 161 Siurry Shield Machines 163 Developments 163 Working Principle 163 Shields with Screw Conveyors 165 Developments 165 Working Principle 165 Machine Types 167 Open Mode (Screw Conveyor - Conveyor Belt) 167 Closed Mode (Screw Conveyor - Conveyor Belt) 167 Closed Mode (Slurry Circuit) 168 EPB Mode (Screw Conveyor -- Conveyor Belt or Screw Conveyor/Slurry Pump) 169 Open Mode (Conveyor Belt) 170 Micro Machines for Hard Rock 172 Mini TBM 172 Pipe Jacking 174 Press-Boring Pipe Jacking 174 Shield Pipe Jacking 174 Special Processes : Combinations of TBM Drives with Shotcrete 177 Scope of App1ication 177 Construction Options 178 Probe Headings 178 Pilot Headings 180 Enlargement for Stations, Points or Machine Halls 181 Examples 183 Piora-Mulde Probe Heading 183 Kandertal Probe Heading 184 Uznaberg Pilot Heading 188 En1argement at the Connecting Structure at Nidelbad Zürich-Thalwil Tunnel 190
Geological Investigations and Intluences 195 General 195 Influences on the Boring Process 199 Influences on the Machine Clamping 202 Influences on the Rock Support 205 Classification for Excavation and Support 207 General and Objectives for Mechanised Tunnel1ing 207 Classification Systems 208 Classification According to Rock Properties 208 RMR System (Rock Mass Rating System) 208 Q System (Quality System) 211 C1assification According to Cuttability and Abrasiveness 220 Classification According to Type, Extent and Location ofthe Support Work Required 222 Standards, Guidelines and Recommendations für the C1assification of Mechanised Tunnel1ing 223 C1assification in Germany, 223 Classification in Austria 228 Classification in Switzerland 234 Classification Suggestion by the Authors 239 Tendering, Award, Contract 243 Procedure Examples 243 Procedure in Switzerland 243 General 243 Tender Evaluation 244 Quality Management 245 Assignment of Risks in the Contract 246 Geological1y or Geotechnically Altered Conditions, Altered Orders, Altered Schedules 249 Procedure in the Netherlands 249 Tendering and Negotiation Procedure with the Botlek Tunnel as an Example 249 Procedure in Germany 252 Design and Geotechnica1 Requirements in the Tendering of a Mechanised Tunnelling as Alternative Proposal 253 Introduction 253 Examples 253 Adler Tunnel 253 Sieberg Tunnel 254 Stuttgart Airport Tunnel 255 Rennsteig Tunnel 257 Lainz Tunnel 258 XI
XII Contents 1423 Additional Requirements for Mechanised Tunnelling Concept in the Tender Documents 260 14231 14232 14233 1424 14241 14242 14243 1425 Geology and Hydrology Design and Construction Process Specification and Contract Decisions Based on Cost Design Phase and Preparation far Tendering Tendering Phase Construction Phase and Final Payment Forecast 261 261 262 262 262 263 263 263 15 151 152 1521 1522 153 1531 1532 15321 15322 15323 15324 15325 1533 15331 15332 1534 1535 15351 15352 1536 15361 15362 1537 1538 15381 15382 15383 15384 15385 154 1541 1542 Tunnel Lining 265 General 265 Design Principles for Tunnel Linings 265 Single-Shell and Double-Shell Construction 265 Watertight and Water-Draining Forms ofconstruction 267 Lining with Concrete Segments 269 General 269 Construction Types 271 Block Segments with Right-Angled Plan 271 Hexagonal or Honeycomb Segments 274 Rhomboidal and Trapezoidal Segment Systems 275 Expanding Segments 276 Yielding Lining Systems 277 Joint Detailing 282 Longitudinal Joints 282 Ring Joints 286 Steel Fibre Concrete Segments 289 Grouting Annular Gap 290 Filling with Gravel 290 Mortar Grouting 291 Measures for Waterproofing Tunnels with Segment Linings 291 Sealing Bands 292 Injecting 294 Segment Production 295 Damages 296 Damage During Ring Erection 297 Damage During Excavation 297 Damage at the Shield Tail Seal 298 Damage after Leaving the Shield 298 Repair of Damage 299 Cast in-situ Linings 299 General 299 Construction 300
Contents XIII 1543 Manufacture 300 155 Shotcrete Layers as the Final Lining 30 I 156 Structurallnvestigations 302 16 Examples of Completed Tunnels 303 161 Tunnel Excavation with Gripper TBMs 303 1611 Contro1 and Drainage Tunnel, Ennepe Reservoir 303 1612 Manapouri Underwater Tunnel, New Zea1and 305 162 Tunnelling with Shie1d TBMs 313 1621 San Pellegrino Tunnel, ltaly 313 1622 Zürich-Thalwi1 Twin-Track Tunnel, Section Brunau-Thalwi1 317 163 lnclined Shaft Tunnelling with Double Shield 321 1631 Cleuson-Dixence Pressure Shaft 321 References 327 Index 337