Tunnel Design

<Session 1>
Tunnel Planning
Nobuharu ISAGO，Dr. Eng.

Professor, Tokyo Metropolitan University
nisago@tmu.ac.jp
Tunnel Planning Seminar, Jakarta, 16 September, 2019 1
<Session 1>
Tunnel Planning
Menu of Session1
1.1 About Tunnel
1.2 Flowchart of Tunnel Construction Project
1.3 Tunnel Planning
1.4 Selection of Road Structure Type
1.5 Geometric Design
1.6 Tunnel Portal
1.7 Tunnel Construction Plan

1.1 About Tunnel

1.1 About Tunnel
Contents
1.1.1 Difference between General Structure and Tunnel

1.1.2 Design and Construction Procedure of Tunnel
1.1.3 Advantage and Disadvantage of Tunnel

1.1.1 Difference between General Structure and Tunnel
<General Structure>
(1) Earth Work
• The road is generally constructed by filling and cutting existing
mountain without structures.
(2) Bridge
• The road is constructed in the air by structure.
<Mountain Tunnel>
(3) Tunnel
• The road is constructed in the mountain to avoid large scale filling and
cutting existing mountain.
(3) (1) (2)

1.1.2 Design and Construction Procedure of Tunnel
General structure Mountain tunnel
Design condition Design condition

Load: Confirmed Load: Unconfirmed
Material: Artificial, Uniform Material: Natural, non-uniform
Material characteristics: Known Material characteristics: Unknown
Design Design Design

Structural design Setting of load is difficult, Support pattern based on
(Confirmation of safety and economy) and evaluation of ground classification
analysis is also difficult
Construction
Construction based on design
Construction
Validity of support is evaluated during
construction stage
Earth pressure on tunnel is complicated and it is
explained only in concept not in quantity.
Measurement
Confirmation of safety and cost efficiency

1.1.3 Advantage and Disadvantage of Tunnel
Advantage of Tunnel
• Risk of road closure is low, as tunnel is constructed under the ground
thus impact of disaster (rock fall, heavy rain, typhoon, gust, snow, etc.)
can be reduced.
-> It is important to locate tunnel portals avoiding disaster-prone area.
Disadvantage of Tunnel
• Load acting on tunnel varies according to the geological condition which
is not homogeneous.
-> It is important to understand geological conditions correctly before
construction.
-> At the same time, it is quite important to understand the limitation of
investigation.


Determination of
Tunnel planning basic elements
Investigation
Ground
Classification Design
Change
Structural design
Observation and
Maintenance and Execution
measurement
operation
Judgment of
Completion of Yes safety and cost
No
construction efficiency
* In tunnel project, design change is usually made according
to the investigation results in the design stage and also
actual geological conditions confirmed during construction.
1.3 Tunnel Planning

1.3 Tunnel Planning
Contents
1.3.1 Matters to be Considered in Tunnel Planning

1.3.2 Tunnel Planning Flow
1.3.3 Evaluation of Optimum Route

1.3.1 Matters to be Considered in Tunnel Planning (1/2)
Matters to be Considered (1)

• Social and economic aspects should be considered in the tunnel
planning.
• In tunnel planning, not only tunnel itself but also access road to the
tunnel should be considered as the whole project road.
• Alternative routes should be evaluated comprehensively considering

traffic safety, topographic conditions, environment, etc.
• It is important for tunnel planning to understand that “Tunnel is part
of the road network”.

1.3.1 Matters to be Considered in Tunnel Planning (2/2)
Matters to be Considered (2)

• Tunnel structures should be planned in consideration of related
tunnel facilities.
• Tunnel facilities such as ventilation system, lighting, emergency

facilities, etc. are provided for the road tunnel to secure traffic safety
as well as driving comfort.
• Tunnel structures and tunnel facilities should be planned at the same
time in order to correctly understand the mutual relations between
structures and facilities.

1.3.2 Tunnel Planning Flow (1/5)
Accuracy of tunnel planning is increased by steps.
<Planning Stage>
• It is important to understand major issues of the project based on
the comprehensive surveys/investigations.
<Design Stage>
• Accuracy of design is increased by steps from preliminary design to
detailed design.

Tunnel Planning Flow
<Flow>
1. Selection of route 2. Selection of alignment 3. Determination of alignment
• 1/50,000 to 1/25,000 map • 1/5,000 to 1/2,000 map • 1/1,000 map
• Economic evaluation • Economic evaluation • Design
• Determination of geometric • Study for items to be • Study for the construction
standard considered • Cost estimates
• Study for major items to be • Study for structures (tunnel,
considered bridge, earthwork)
• Study for major structures
<Surveys/Investigations>
Analysis of existing data and Field investigations Field investigations
materials • Large scale landslide • Issues in earthwork section
• Topographic condition • Slope • Issues in tunnel section
• Geological condition • Conditions at tunnel portal Ground condition survey/Investigation
• Meteorological condition area • Ground stability
• Disaster • Existing structures • Small scale landslide
• Environment • Soft soil • Foundation ground for structures
• Landuse • Environment • Geological condition for tunnel
• Past Construction section
Geological investigation
• Elastic Wave Probing
Low <Accuracy Level> High • Boring survey
Tunnel Planning Seminar, Jakarta, 16 September, 2019 • Laboratory test 15
1. Selection of Route
<Matters to be considered>
• Social needs
• Economic benefits
• Project scale
• Technical issues
<Topographical map> ALT-C1

• 1/50,000 to 1/25,000 ALT-E1
ALT-E2
ALT-E3
<Survey/Investigation>
• Analysis of existing data ALT-E4
and materials ALT-C2

++ Selection of Route (Example) ++
Item ALT-C1 ALT-C2 ALT-E1 ALT-E2 ALT-E3 ALT-E4
Total Tunnel Length 11.3km 10.7km 8.3km 9.7km 9.6km 6.5km
Total Bridge Length 7.5km 4.1km 3.0km 4.5km 2.7km 3.9km

2.4% 2.4%
Average Vertical Gradient (Accident, (Accident, 1.5% 1.6% 1.4% 1.6%
Slow speed) Slow speed)
High
High High
(Long tunnel +
Construction Cost (Long tunnel + (Long tunnel + Low Fair Low
bridge length)
bridge length) bridge length)
High
High High
Construction Difficulty Fair Low Fair (Many large Low (Many large
scale bridge) scale bridge)
High (Long
Impact on Natural Environ. Low Low Fair Low Low earthwork +
bridge length)
High (Passing High (Passing
Impact on Social Environ. Low Low Low Low
town/village) town/village)
ALT-C1, ALT-C2, ALT-E2 and ALT-E4 have some disadvantage.

ALT-E1 and ALT-E3 go to next step (Selection of Alignment).
2. Selection of Alignment
<Matters to be considered> <Items to be considered for alignment selection>
• Items to be considered for • Existing landuse and future landuse plan
alignment selection • Connection with other roads
• Traffic safety (alignment) • Relation with railway
• Type of structures • River crossing
• Environment • Alignment in the mountain
• Issues for construction • Geological conditions
• Natural and social enviroment
<Topographical map>
• 1/5,000 to 1/2,000
<Survey/Investigation>
• Field investigations

3. Determination of Alignment
<Matters to be considered>
• Optimum alignment
• Determination of structure
type
• Road geometric design
• Structural design At valley
• Cost estimates Diagonally
to mountain
<Topographical map>
• 1/1,000 Shallow earth cover
in this area at portal
<Survey/Investigation> At steep slope

• Geological investigations

++ Determination of Alignment (Example) ++
Item ALT-E1 ALT-E1R
Total Tunnel Length 7.5km 7.8km
Total Bridge Length 0.9km (0.6km of large scale bridge) 1.8km (0.3km of large scale bridge)
Not stable and durable Stable and durable
Tunnel Portal
Gradient change (Risk for traffic accident) 1 gradient
Vertical Grade in
Tunnel
Fair (Longer total bridge length, but almost

Construction Cost Fair
bridge is small scale bridge)

++ Items to be Considered for Tunnel Planning ++
Hydraulic conditions
River, Lake, Pond

Poor ground properties: Water inflow
swelling, squeezing,
Fault Zone unconsolidated etc.
rare species
heritage
Geological conditions
rock fall
Residential zone
Environmental
landslide slope failure conditions
infrastructure
Topographical conditions Urban conditions

++ Risk Factor (1/2) ++
1. Landslide 2. Fault
Fault
Tunnel Tunnel
3. Unconsolidation 4. Water inflow

Excavation→loosening earth pressure
Ground water
level
Tunnel
Excavation Water inflow
Fault
22

++ Risk Factor (2/2) ++
5. Crack 6. Submergence collapse
collapse Tunnel Tunnel
7. Squeezing, Swelling 8. Inflammable gas explosion

Large earth pressure
Tunnel
Inflammable
Excavation gas

1.3.3 Evaluation of Optimum Route
Optimum route is selected based on the evaluation of alternative

routes from comprehensive views.
<Economic View>
• In addition to construction cost and operation & maintenance cost,
benefit to road users by improving travel condition and social loss
reduction by decrease in traffic accidents should be evaluated.
<Safety View>
• Safety for construction, safety for road users, safety against disasters,
etc. should be evaluated.
<Environmental View>
• Impact on local community, natural environment, economic activity,
etc. should be evaluated.

++ Impact on Surrounding Environment ++
If groundwater level lowers by tunnel construction, significant issues
would occur.
Cloud
Rain-fall Water inflow

Evaporation
Evaporation
Well up
Effluent seepage ground

subsidence
Reduce the
industrial water
Reduce the water
of river Reduce the
agricultural water
++ Vertical Alignment ++
Declining Outward to Both Declining Inward from
Declining One-side
Sides Both sides
Sketch
：Water flow
Method Gravity flow Gravity flow Forced drainage by

pumping
Drainage
Direction Pit mouth at lower Both pit mouths Either pit mouth
altitude
・Desirable to construct ・Possible to construct
Advantage from the pit mouth at from both pit mouths None
lower altitude
・Due to drainage by
pumping, it requires more
・If construction goes in construction and
Disadvantage ・Spring water flows down one direction, part of the maintenance costs (during
only to one pit mouth construction is performed and after construction)
on downward pitch ・Construction is
performed on downward
pitch.
Evaluation Good Bad

1.4 Selection of Road Structure Type

1.4 Selection of Road Structure Type (1/3)
The following matters should be considered in the horizontal alignment

study.
• Impact on existing properties such as houses, buildings, etc.
• Important facilities such as cultural asset, mosque, electricity pylon,
etc.
• Area where topographic or geological issues arise.
Road length: 1km

Tunnel Route Compared to earthwork, tunnel
structure can achieve above-
mentioned matters.
Also,
• Good alignment can be provided.
• Risk for disaster can be minimized.
• Impact on natural environment
Road length: 2km
can be reduced.
The following matters should be considered in the vertical alignment

study.
• Construction cost
• Cut and fill volume balance
• Balance between tunnel and bridge length/height
Long and
Short tunnel high bridge
Long tunnel
Short and low

bridge
• Construction cost of earth work has been increasing in recent years
to meet a growing need of safety (countermeasure for disaster) and
protection of environment (planting on slope, etc.).
• Construction cost of tunnel has been decreasing due to the
technological development.
<Before> <Now>
Environment
Construction Cost
Safety
Bridge
Safety Bridge
Tunnel
Tunnel
Embankment
Embankment
Cut
Cut
Land Land
Land acquisition Land
acquisition
acquisition acquisition
Earth Work Bridge/Tunnel Earth Work Bridge/Tunnel

1.5 Geometric Design

1.5 Geometric Design (1/3)
Tunnel class is determined according to road class of the project.
<Geometric condition in road class> <Geometric condition in tunnel class>

1. Horizontal/Vertical alignment 1. Horizontal/Vertical alignment in tunnel section
2. Cross section 2. Cross section in tunnel section
3. Horizontal/Vertical clearance 3. Horizontal/Vertical clearance in tunnel section
Tunnel class
Clearance
Traffic Volume (veh/day, per tunnel)

8,451veh/day
Cross section
Tunnel Length (m)

Horizontal alignment considering project area conditions (Example)
Avoiding the followings

Avoiding the followings • Hot spring
• Residential area • Hot spring facility
• School Area possible to adjust the alignment • Park
Hot spring
Facility Park
Residential
area
Hot spring
School
Residential
area
Area where adjustment of alignment is limited

Vertical alignment considering project area conditions (Example)
Clearance Clearance Max. vertical

with road with road gradient in IC
Clearance section
with culvert Securing enough
Clearance earth cover
Connecting
to road with road
Min. vertical
gradient
Min. vertical Clearance

Clearance Min. vertical gradient with culvert
with culvert gradient

1.6 Tunnel Portal

1.6 Tunnel Portal
Contents
1.6.1 Position of Tunnel Portal

1.6.2 Countermeasure to Construct Tunnel Portal
1.6.3 Matters to be Considered in Tunnel Portal Position

1.6.1 Position of Tunnel Portal (1/2)
• Difficulty level of construction at pit mouth varies greatly

depending on positional relation between geography and
tunnel axial direction.
(1) Perpendicular to contours-type -> Easy

(2) Diagonal to contours-type -> Easy
(3) Parallel to contours-type -> Difficult
(4) Penetrating the ridge-type -> Easy
(5) Penetrating the valley-type -> Difficult
(2)
(1) (5)
(4) (3)

1.6.1 Position of Tunnel Portal (2/2)
• Difficulty level of construction at pit mouth varies greatly

depending on positional relation between geography and
tunnel axial direction.
(1) (2) (3) (4) (5)
Perpendicular to Diagonal to Parallel to Penetrating the Penetrating the
contours-type contours-type contours-type ridge-type valley-type
Cross-
section
Earth Deep Deep Shallow Deep Shallow

covering
Small earth
None in Unsymmetrical Unsymmetrical None in covering,
Problem particular earth pressure earth pressure particular thick
unconsolidated
layer
Evaluation Most ideal Avoid if possible Avoid as much Generally stable Consider
order as possible carefully

1.6.2 Countermeasure to Construct Tunnel Portal

1.6.3 Matters to be Considered in Tunnel Portal Position (1/4)
In case tunnel portal is located at valley
③
②
④
⑤
Issue
Risk that soil flows into the tunnel
portal by landslide
Countermeasure
Making the soil flow above the tunnel
by extending tunnel

In case tunnel portal is located at valley Countermeasure for landslide
Fixing rock bolt and ground
improvement by grout injection
Countermeasure for rockfall

Providing countermeasure method based
on the detailed survey/investigations
Issue
Risk of landslide and rockfall
Countermeasure
Providing auxiliary method for landslide and
prevention work for rockfall
In case tunnel is constructed in thick soil/sand layer
Talus and debris

flow deposit area
Issue
Unstable tunnel facing during
tunnel excavation
Countermeasure
Confirming the safety of tunnel

facing by numerical analysis
Avoiding the risk of collapse by
auxiliary method
In case tunnel is constructed diagonally to the mountain
Issue
Imbalanced earth pressure to the tunnel
Countermeasure
Evaluating effect of imbalanced earth pressure to
the tunnel by numerical analysis
Decreasing earth pressure by auxiliary method

Contents
1.7.1 Construction Road Plan

1.7.2 Construction Vehicle Operation Plan
1.7.3 Construction Schedule Plan
1.7.4 ICT Construction Plan

1.7.1 Construction Road Plan (1/4)
In case there is no existing access road to tunnel construction site
Issue
There is often no existing access road to the tunnel construction site, as the mountain tunnel is
constructed at area distant from residential area.
Countermeasure
Construction road connecting existing road and tunnel construction area is constructed. Its geometric
conditions such as alignment, cross section, etc. are determined inconsideration of size of construction
vehicles, construction vehicle traffic volume, topography, etc.
Tunnel portal
Cut
Construction road Cut
Construction road

In case large scale construction road is required
Issue
In case the construction road is constructed in the mountain, large scale cut and fill or temporary bridge
may be required. These types of construction road need more construction period and cost.
Large scale cut and fill
Temporary bridge
Construction
road Valley

Countermeasure (1)
A part of permanent earth work section is constructed first, and its section is utilized as the construction
road for the tunnel.
Advantage: Additional construction is not required as the construction road is constructed as a part
of permanent works.
Disadvantage: Remaining section of earth work can not be commenced until the tunnel construction is
completed.
Cut for Permanent cut line

construction road
Permanent earth work

Countermeasure (2)
Small size tunnel is constructed first to utilize as the construction road.
Temporary tunnel for access to middle of
Small size tunnel for 1 tube out of 2 tubes
tunnel
Tunnel
本線トンネル
Tunnel
本線トンネル貫通側工事
Construction work
Constriction 1
工事① Constriction
工事➁ 2
Image
本線内導坑（全線施工）
Temporary tunnel
Temporary
作業横坑
tunnel
本線内導坑（部分施工）
Temporary tunnel
Tunnel is constructed from 2 locations Small size tunnel can be constructed

Advantage earlier, and can be utilized as the
construction road
Additional cost is necessary for temporary Small size tunnel can not be expanded to
Disadvantage tunnel. ultimate size during it is being utilized as
Temporary tunnel must be filled after use. the construction road.
++ Small Size Temporary Tunnel (Example) ++
■Small size temporary tunnel（NATM / New Austrian Tunnel Method） Ultimate size
Temporary
■Small size temporary tunnel（TBM / Tunnel Boring Machine）

1.7.2 Construction Vehicle Operation Plan
In case exiting roads are utilized as the construction road
Issue
In case existing roads are utilized as the construction road, negative impact on living environment along
the construction road may occur.
Flow of tunnel excavated soil
<Tunnel excavation site> <Temporary soil deposit site> <Soil disposal site>
Within construction area Utilizing existing road
Countermeasure
Construction road is planned in consideration of geometric condition, traffic
Temp. soil deposit site
condition, environment, etc. of the existing road. Countermeasure such as
widening is made, if necessary.
Advantage Disadvantage Countermeasure
• Reduction of cost • Traffic congestion • Widening
• Shortening of • Traffic accident • Passing bay
construction period • Noise and vibration • Specific pavement
Tunnel Planning Seminar, Jakarta, 16 September, 2019

Utilizing existing road 51
1.7.3 Construction Schedule Plan
Issue
Construction schedule of the mountain tunnel depends on geological condition and environmental
condition in addition to construction road plan.
Countermeasure
Geological condition and environmental condition are fully considered before the construction.
Items to be Considered Note

Geological • Selection of tunnel support • Accuracy of geological investigations
condition • Selection of auxiliary should be enhanced by steps.
construction method • Risk and its countermeasure should be
• Selection of excavation method considered from the geological
investigations results.
Environmental • Countermeasure against noise • Restrictions in the construction method
condition and vibration such as night construction, blasting
excavation, etc. may be given.

1.7.4 ICT Construction Plan
In case ICT (Information and Communication Technology) constriction is applied
Issue
Measurement of
It is difficult to understand detailed geological conditions during tunnel shape
planning stage.
Countermeasure
Geological investigations are conducted by steps according to each
project stage.
Items to be Confirmed Reflecting in construction

Measurement • Tunnel shape • Change of tunnel support
• Safety of tunnel support • Change of construction method
• Safety of other tunnel facilities • Adding auxiliary construction method
Observation • Understanding the difference • Change of tunnel support
between actual geological • Change of construction method
conditions and those expected • Adding auxiliary construction method
in the planning stage
• Risk of collapse
Additional • Risk of geological condition in • Confirmation of geological condition by
surveys front of tunnel facing boring
• Additional countermeasure
Thank you for your attention
Terima kasih banyak

Tunnel Design

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Tunnel Design

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<Session 1>

Nobuharu ISAGO，Dr. Eng.

Tunnel Planning Seminar, Jakarta, 16 September, 2019 2

Tunnel Planning Seminar, Jakarta, 16 September, 2019 3

1.1.1 Difference between General Structure and Tunnel

Tunnel Planning Seminar, Jakarta, 16 September, 2019 4

(3) (1) (2)

Tunnel Planning Seminar, Jakarta, 16 September, 2019 5

Design condition Design condition

Design Design Design

Tunnel Planning Seminar, Jakarta, 16 September, 2019 6

Tunnel Planning Seminar, Jakarta, 16 September, 2019 7

Tunnel Planning Seminar, Jakarta, 16 September, 2019 8

Tunnel Planning Seminar, Jakarta, 16 September, 2019 10

1.3.1 Matters to be Considered in Tunnel Planning

Tunnel Planning Seminar, Jakarta, 16 September, 2019 11

Matters to be Considered (1)

• Alternative routes should be evaluated comprehensively considering

Tunnel Planning Seminar, Jakarta, 16 September, 2019 12

Matters to be Considered (2)

• Tunnel facilities such as ventilation system, lighting, emergency

Tunnel Planning Seminar, Jakarta, 16 September, 2019 13

Accuracy of tunnel planning is increased by steps.

Tunnel Planning Seminar, Jakarta, 16 September, 2019 14

<Topographical map> ALT-C1

and materials ALT-C2

Tunnel Planning Seminar, Jakarta, 16 September, 2019 16

Total Tunnel Length 11.3km 10.7km 8.3km 9.7km 9.6km 6.5km

Total Bridge Length 7.5km 4.1km 3.0km 4.5km 2.7km 3.9km

ALT-C1, ALT-C2, ALT-E2 and ALT-E4 have some disadvantage.

Tunnel Planning Seminar, Jakarta, 16 September, 2019 18

<Survey/Investigation> At steep slope

Tunnel Planning Seminar, Jakarta, 16 September, 2019 19

Total Tunnel Length 7.5km 7.8km

Not stable and durable Stable and durable

Gradient change (Risk for traffic accident) 1 gradient

Fair (Longer total bridge length, but almost

Tunnel Planning Seminar, Jakarta, 16 September, 2019 20

River, Lake, Pond

Tunnel Planning Seminar, Jakarta, 16 September, 2019 21

3. Unconsolidation 4. Water inflow

Tunnel Planning Seminar, Jakarta, 16 September, 2019 22

5. Crack 6. Submergence collapse

collapse Tunnel Tunnel

7. Squeezing, Swelling 8. Inflammable gas explosion

Tunnel Planning Seminar, Jakarta, 16 September, 2019 23

Optimum route is selected based on the evaluation of alternative

Tunnel Planning Seminar, Jakarta, 16 September, 2019 24

Rain-fall Water inflow

Effluent seepage ground

Method Gravity flow Gravity flow Forced drainage by

Tunnel Planning Seminar, Jakarta, 16 September, 2019 26

Tunnel Planning Seminar, Jakarta, 16 September, 2019 27

The following matters should be considered in the horizontal alignment

Road length: 1km

The following matters should be considered in the vertical alignment

Short and low

Earth Work Bridge/Tunnel Earth Work Bridge/Tunnel

Tunnel Planning Seminar, Jakarta, 16 September, 2019 31

<Geometric condition in road class> <Geometric condition in tunnel class>

Traffic Volume (veh/day, per tunnel)

Tunnel Length (m)

Tunnel Planning Seminar, Jakarta, 16 September, 2019 32