One-pass and Two-pass Precast Segmental Linings

Wern-ping (Nick) Chen Jacobs

UT Austin Seminar, April 4, 2007

Applicable to:
Tunnel Boring Machine (TBM) tunneling

Not for:
Hand mining, such as drilled and blast or excavation by roadheader or other mechanized means Presentation starts from big questions and narrows down to details

Outline
1. Definitions 2. Factors that drive the use of segmental lining 3. Tunnel alignments 4. Rationale for choosing one or the other 5. Types of precast segmental linings/Material 6. Geometries 7. Segment joints 8. Segment construction tolerance 9. Design/Modeling 10. Construction considerations 11. References 12. Q/A

1. Definitions
Primary/initial lining
The ground support installed immediately after the excavation It is a temporary structure for safety and operation during tunneling Normally in associated with hard rock tunneling Examples are rock dowels, steel set, or shotcrete

1. Definitions
Secondary/final lining
Tunnel support or lining installed following and independent of excavation to satisfy user/function requirement Normally it is cast-inplace concrete

1. Definitions
One-pass lining
Lining used as both initial support and final lining of a tunnel; normally it is precast segmental lining

1. Definitions
Two-pass lining
With primary/initial support installed as temporary ground support and followed by an insitu final concrete lining

1. Definitions
Two-pass Segmental lining
Use segmental lining as initial ground support and cast-inplace (CIP) concrete as final tunnel lining

1. Definitions
TBM Shield/Segment

Segment, Open Face, Single Shield

TBM Shield/

1. Cutterhead 2. Shield 3. Articulation (option) 4.Thrust ram 5. Segment erector 6. Muck extraction conveyor 7. Muck transfer Conveyor 8. Gathering arm 9. Muck hopper 10. Motor 11. Tailskin articulation (option) 12. Thrust ring

Schematic Earth Pressure Balance Machine (EPBM)

Schematic Slurry Shield Machine

Open Gripper TBMs

1. Definitions
Main Beam TBM
The family of open TBMs is developed for excavating in rock. The thrusting force is obtained by reacting on the grippers. The head is equipped with cutting disks.

1. Cutter head 2. Cutter head shield 3. Erector to place rib and mesh 4. Inner kelly 5. Outer kelly in two positions with grippers and telescope jacks 6. Push jacks 7. Cutter head drive 8. Rear support 9. Belt conveyer 10. Roof bolting drill 11. Probe drill

2. Factors that drive the use of segmental lining

Ground stability during tunneling 1. Soft ground tunneling 2. Adverse geological condition in hard rock tunneling; such as in laminated shale, embedded with clay Construction schedule pending on the contractor, the construction schedule may be reduced Potential of excessive groundwater infiltration

2. Factors that drive the use of segmental lining

Case Study - Upper Rouge Tunnel Project Limy Shale Fissile (disking) behavior; 30 ft ID

Notes: To be cost effective of employing a TBM, the length of the tunnel shall be roughly greater than 1.2 miles (2 Kilometer) long Generally speaking, the cost of a two-pass lining is lower than the onepass segmental lining

2. Factors that drive the use of segmental lining

URT case study Original design Rock dowel and steel rib as initial ground support with CIP concrete final lining Final design Revised to one-pass or two-pass segmental lining

URT Shallow cover tunnel in Antrim Shale

3. Tunnel alignments
Horizontal public right of way; geological
features; 3rd party issues (transportation and muck handling); distance/function

4. Rationale for choosing one or the other

One-pass Segment Advantages:
Smaller excavation diameter Better concrete quality control (precast) May shorten tunnel total construction schedule (but longer mucking duration) Robust designed for the worst ground condition Less water treatment required (TSS &Ph)

Vertical cover above tunnel crown; 1 to 2 D,

pending on ground condition (design issue); function/operation; geological condition

Radius of curvature of tunnel

Diameter of TBM (D) in meters 10 7 4 Minimum Radius of curvature in meters 400 300 80

4. Rationale for choosing one or the other

One-pass Segment Disadvantages
Higher cost Tight alignment tolerance/control Difficult to repair Difficult interface design and construction Relatively delayed initial support

4. Rationale for choosing one or the other

One-pass Segment Disadvantages
Quality of installed bolted/gasketed system Tight segment construction & installation tolerance Need to patch bolt pockets and caulking groves (water/wastewater tunnel) Segment flotation during construction Bolt corrosion (water/wastewater tunnel) Design consideration for internal pressure at gaskets (water/wastewater tunnel) Maintenance
Radial Joint Detail

Gasket Precast Segment

4. Rationale for choosing one or the other

Two-pass Segment Advantages
Robust initial ground support Easier alignment control Less joints in final lining Easier interface design and construction

4. Rationale for choosing one or the other

Two-pass Segment Advantages
Less stringent construction tolerance; easy for erecting Easier alignment control Highest TBM production rate

Pattern Dowels

4. Rationale for choosing one or the other

Two-pass Segment Disadvantages
High cost if not using junk segment Design the worst ground condition for initial support ($) Few, about four (4) in the US, contractors have done junk segment The largest expanded segment in the US is NBC of 26 ID tunnel Required more contact grout
2 1.8 1.6 1.4 1.2 1 0.8

URT South Tunnel Cost Analysis

Two-pass ExpandedSegment

Two-pass - Dowels & Rib

South Tunnel Baseline - 30-ft ID; 19,000 ft long; 20% steel rib + 6 shotcrete ; 20% 16 pattern dowels with mesh; 12 dowels and mesh for the rest of the tunnel

5. Types of precast segmental linings/Material

5. Types of precast segmental linings/Material

Selection of segment type to suit the tunnel usage, ground condition, construction methods, and cost. For present time in US, concrete segment is the most popular one (highest compression capacity, but is the heaviest for handling)

(RC/FRC)

Cross Section of Segments

One-pass segment

Two-pass Rib only

5. Types of precast segmental linings/Material

5. Types of precast segmental linings/Material

As light (thin) as possible High strength concrete (> 6,000 psi) to accommodate shear force Low W/C ration (>0.4; 0.35 is normal); Adding silica film or fly ash, as cementitious replacement to Portland cement, to reduce permeability; however, with the consequence of excessive spalling in a fire event Small rebar cover to avoid spalling and chipping during erection (1 to 11/2 cover) Consider fiber to prevent cracking

Segment Components

5. Types of precast segmental

linings/Material

5. Types of precast segmental linings/Material

Spalling of joints

Cracking and splaaing during erection

Welding a segment cage for a large diameter highway tunnel

Segment cage for a large diameter highway tunnel

6. Geometries

6. Geometries

Cross Section

Side View

K segment inserted in radial direction

K segment inserted in longitudinal direction

6. Geometries
r = k /2 + - determined based on
workability and design to transmit thrust; as small as possible; it is about 2 -5o; 3o is recommended

6. Geometries
l - based on construction consideration; the length of the shield; and the length of the segment; normally from 17 -20o l = 0o

Segment inserted in radial direction

Section a-a

Segment inserted in longitudinal direction

6. Geometries
Shape and width of segments normally based on handling and transportation considerations

6. Geometries
Shape and dimensions of steel segment (in mm)

The thickness is normally determined from design requirements

6. Geometries
Shape and dimensions of concrete segment (in mm)

6. Geometries
Case 1 - key segment inserted in radial direction

Thickness is based on security load case

6. Geometries

6. Geometries
Case 2 - key segment inserted in longitudinal direction

6. Geometries
Tapered ring to accommodate curved tunnel alignment/or alignment adjustment

6. Geometries

6. Geometries

6. Geometries

7. Segment Joints
Circumferential Joints Radial Joints

7. Segment Joints

Curve bolt (out of date)

Straight bolt and sleeve

Dowell

Shear Cone

7. Segment Joints
Connection by drifting

7. Segment Joints

Dowell

Radial joint by bolt and sleeve Circumferential joint by dowel

7. Segment Joints

7. Segment Joints

Radial joint by rod

Circumferential joint by cone

7. Segment Joints Gasket Seal

7. Segment Joints Gasket Seal

T configuration testing

Elastomeric gasket Typical pressure curve for a given displacement Typical load deflection curve

7. Segment Joints Gasket Seal

The selected gasket must meet watertightness rating and tolerance specified

8. Segment Construction Tolerance

8. Segment Construction Tolerance

8. Segment Construction Tolerance

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8. Segment Construction Tolerance

8. Segment Construction Tolerance

Sample ring built (normally without gasket)

9. Design/Modeling Beam/FEM

9. Design/Modeling
Radial joint model:
Empirical formula by Allan Muir-Wood (1975) homogenous rigid ring by reducing the bending I = IS + In (4 / m) I reduced area-wise moment IS area-wise moment of the force transmission zone In area-wise moment of complete section m number of segments (small key-segment not counted)

Solid beam with full or partial bending rigidity

Other joint simulations:

Ring with hinges Ring with shear and rotational springs Radial Janssen (1983) Circumferential - Gijsbers and Hordijk (1997)

9. Design/Modeling
Design Loads:
Ground load soil, long term rock, rock wedge Hydrostatic pressure Functional vehicular (highway, transit), surge (water/wastewater), insert support (M&E, Utility) Contact grouting pressure - > 30 psi net (offset the groundwater pressure) Construction loads stacking, lifting/transportation, jacking, gasket compression

9. Design/Modeling

Moment distribution because of the joints Stacking load

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9. Design/Modeling construction loads

9. Design/Modeling construction loads

Lift/Grout socket

Lifting load
Contact grout

9. Design/Modeling

construction loads

9. Design/Modeling construction loads

Ring erector

Jacking load

9. Design/Modeling construction loads

10. Construction Considerations

Work Shaft
Work shafts shaft size to accommodate TBM access and exist, specifically considering the shield size and its interaction with vent duct, convey belt, and other utilities in the shaft during construction.

EPDM (Ethylene Propylene Diene Monomer) gasket compression

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10. Construction Considerations

Work Shaft
Length of tail section

10. Construction Considerations

Work Shaft
Length (L) to Diameter (D) Ratio

L/D

Cutter outside diameter (mm)

10. Construction Considerations

lining placement
Lifting lug

10. Construction Considerations

lining match mark

Match Marks

Segment ID

10. Construction Considerations

Contact Grout
or by volume Removable Lifting Insert

10. Construction Considerations

Contact Grout

Grouting Criteria by refusal

Grout Tube

Non Return Valve

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10. Construction Considerations

Tunnel Break-in

10. Construction Considerations

Tunnel Break-in (launching pit and cradle)

Mostly required in soft ground tunnelling

10. Construction Considerations

Break-in, TBM Jacking Frame
Front/Middle/ Tail shields with Jacking Frame

10. Construction Considerations

Break-in, TBM Jacking Frame

TBM Tail Initial Lining

10. Construction Considerations

10. Construction Considerations

Tunnel Break-out

Tunnel Break-in (w/o ground modification)

Mostly required in soft ground tunnelling

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10. Construction Considerations

Tunnel Break-out

10. Construction Considerations

Tunnel Break-out

Receiving Pit

10. Construction Considerations

Tunnel Break-out

10. Construction Considerations

Tunnel Break-out

10. Construction Considerations

Tunnel Break-out

10. Construction Considerations

Tunnel Break-out (w/o ground modification)

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10. Construction Considerations

Tunnel Break-out (w/o ground modification)

10. Construction Considerations

Obstructions headache to the shield tunneling in
soft ground; identified and removed as soon as possible or baselined

Contract documents
Specifications GC; DRB, VECP, EBD, Division 1, technical specifications, measurement and payment Drawings GBR baseline for DSC GDR Alternative Bid concept

11. Reference
1. 2. 3. 4. 5. Design Philosophy of Concrete Linings for tunnels in soft soils by C.B.M. Blom, 2002. Gijsberg, F.B.J., Hordijk, D.A., 1997, Experimenteel onderzoek naar het afschuifgedrag von ringvoegen,TNO-rapport COB K111 ITA Guidelines for the Design of Tunnels, in Tunnelling and Underground Space Technology, 1988 ITA Guidelines for the Design of Shield Tunnel Lining, in Tunnelling and Underground Space Technology, 2000 Janssen, P., 1983, "Tragverhalten von Tunnelausbauten mit Gelenktbbings", Report-No. 83-41 University of Department of civil engineering, Institute for structural analysis. Japan Society of Civil Engineer 1996. Japanese Standard for Shield Tunneling. Muir Wood, A.M., 1975, "The circular tunnel in elastic ground", Gotechnique 25(1) Tunnel Boring Machines, Trends in Design & Construction of Mechanized Tunnelling. 1996 Specification and Guidelines for the use of Specialist Products in Mechanized Tunnelling (TBM) in Soft Ground and Hard Rock, EFNARC, April 2005.

Q and A Nick.Chen@Jacobs.com

6. 7. 8. 9.

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