PE iy We area eyLe med arid Ce MMOL ITAL Pe mL Lp Martin Herrenknecht Ulrich Maid! Gerhard Wehrmeyer (@WILEY-BLACKWELL eegot co, a ICH: BREAKTHROUGH AT THE DIAMETER LINE. i Mie rm was completed on Noverber 22, 2010. (inberg Tunnel withthe con ‘After only two years of tunneling, th ‘The tunnel workers reached the taget shaft of vertble S-461 Herrenknecht Mixshield (2 11.26m) The tunne! will connect the Oerliton station withthe new Lawenstrasse under aground station rectly beneath the main station Hauptbahnhof. It forms the core part of the Diameter Line, a dual track railway connection right beneath city. The pacity of the Zurich main station will increase by 100,000 passengers per day fer the opening which is scheduled for 2010. “The experienced tunellers mastered the tunneling procedure with the high-tech machine beneath the city cater safely and successfully. Goth the tunneling in hard rock and inthe final, particularly demanding around 150 meters beneath the Limmat Fiver in unconsolidated rock and groundwater were mastered Herrenknechtis proud to have been involved again in an outstanding and chal- lenging Swiss tunnel construction project after its participation in other project, such as, for example, the Isisberg Tunnel, the Zimmerberg Base Tunnel and the Gottharé Base TunnelThe authors 1 Introduction ‘Support of the cavity and settlement Construction and design methods Excavation tool and excavation process 7 Muck removal The tunnel lining, Shield tal sealing, grouting works Open shields Compressed air shields 10 Slurry shields 11 Earth pressure shields 12. Convertible shields 13 Special shields and special processes 14 Guided microtunnelling processes 15 Surveying and steering 16 Workplace safety 17. Partnering contract models and construction 18 Process controlling and management 19. DAUR recommendations for the selection of tunnelling machines B. u. G. M. G M ezerpececze pare eces Maidt Maid Wehrmeye: Herrenknecht Wehrmeye- Herrenknecht Wehrmeyer Mail Wehrmeyer Maial Mail Mail Maid Maidl Maia! Maidl Herrenknecht Wehrmeyer Mail Maial Maid MaialThe rapid progress of mechanised tunnelling to market leadership has continued — even exceeded predictions; the general worldwide trend in construction towards mechanisation. and automation clearly demanded a similar development in tunnelling, Its signiicant that, even in Austria, the traditional home of the New Austrian Tunnelling Method (NATM), mechanised tunnelling has also established its position in the last decade. Occupational health and safety, faster advance rates, improved cost security and labour-saving opened opportunities for mechanised tunnelling on a few major projects ~ normally in competi- tion with conventional construction methods. So it is appropriate that this book should now be revised, 20 years after its firs: publica tion. The extent of innovations and practical experience led to a complete reworking. Inei- dentally, the book “Hardock Tunnel Boring Machines“, which appeared in 2008, already offered access to the newest technology in the area of tunnel support. The team of authors hhas adapted the content to the latest technology and has been supplemented to provide the necessary specialist knowledge. The original authers B. Maidl and M. Herrenknecht also worked on this edition. We have gained my son Dr.-Ing, U. Maid! and my former doctoral candidate Dr.-Ing. G. Wehrmeyer, ‘who have particularly devoted themselves to new developments, 1am very thankful that I could still rely on the help of my former employees Herr H. ‘Schmidt and Hew G. Kauflold for tre new revision. I would like to thank Herr Dipl-Ing, M. Griese from MTC, who helped a great deal with the detailed work and overall coordi nation. I would also like to thank my grandson Max Maial for his assistance. A thank-you to all, especially the author colleagues and the publisher. Bochum, January 2011 Bernhard MaidlTable of Contents ‘The authors ....... . VIL Foreword to the 2nd Edition we IX Introduction... ccc ccseeceereeeeeeee : 1 Basic principles and terms . .3 12 Types of tunnel boring machine according t DAUD -.... 2.2... 121 Categories of tunnelling machines German association for | ‘underground construction (TVM) . 1.22 Tunnel boring machines (TBM) 1.22.1 ‘Tunnel boring machines without shield (gripper TBM) 1.222 Reamer tunnel boring machines (ETBM).. 1223 Tanne boring machines wit singe shield (TBMCS) 1.23 Double shield machines (DSM) . coe 1.24 Shield machines (SM)... 1.24.1 Shield machines with full-face excavation (SM-V) . 1.242 Shield machines with partial face excavation (SM-T) 1.25 Adaptable shield machines with combined process technology (KSM).:. we oe 1.26 Special types ... 126.1 Blade shields 1.26.2 Shields with multiple cireular cross-sections... 1.263 Articulated shields. : 1.27 Remarks about the individual types of tunnelling machines. with diagrams. 1.27.1 Tunnel boring machines (TBM) . ceca CO 1.27.2 Double shield machines (DSM) ......... “ B 1.27.3 Face without support (SM-VI) v0 ....cccececseceeeeee B 1.27.4 Face with mechanical support (SM-V2) wine 14 1.27.5 Face with compressed air (SM-V3). 4 1.2.7.6 Face with slurry support (SM-V4)...0. 0. ceveceesseneee 4 1.27.7 Face with earth pressure support (SM-V) 4 1.27.8 Face without support (SM-TI) .......ccccceseeveeees 15 1.279 ace with partial support (SM-T2) . 15 1.27.10 Face with compressed air support (SM-T3) ..... 15 1.27.11 Face with slurry support (SM-TA).... wie 16 1.27.12 Adaptable machines (KSM) mace 16 1.3 Origins and historical developments ......0..2..0.0005 soe 16 2 Support of the cavity and settlement ........ 23) Summort ofthe face... aXil___ttieofConans TableotContents Xl 2.1.3 Compressed air support 26 5 Muck removal 2.414 Slurry support 28 5.1 Preparation for transport. 2.15 Earth support... 32 52 Removal from the face. : 2.16 Calculation models 32 52.1 Open shield machines event toa 95 22 Support ofthe cavity at the shield 37 52.2 Shield machines with pressure chamber ...2.2...20scseseease 9S 23 Support of the cavity behind the shield 37 53, Transport along the tunnel and up shafts. wamaswsvet en 211 24 Settlement and damage classifications 39 S31 Opentransport.. ee. .s2+ a sawensrase 11 24.1 Empirical determination of te settlement. : 41 53.2. Piped transport. . 102 2.42 Numerical models forthe calculation of settlement . 2B 54 Quantity determination and messing equipment... ese. 195 2.5 Heave and compaction 46 55 DF cairns +106 55.1 Separating process a = 108 3 Design and calculation methods. 47 55.2 Separating devices... TOI os 3.1 Constructional parts of the shield. a 5.6 Suitability of the muck for landfill... 21s 3.2 Loading on the shield 30 3.2.1 Loading on the shield skin, . SI 6 The tunnel 17 32.2 Loading on the pressure bulkhead. .3 6.1 General. fees 32.3 Loading from the thrust cylinders st 62 Construction principles forthe tunnel ning aneneony “118 3.3 Calculation of the necessary thrust force « : : a 62.1 Single-layer and Double-layer construction “ mis 33.1 Resistance to advance trough friction on the sveld skin. 2... 55 62.2 Watertight and water draining construction, 29 33.2 Resistance to advance atthe front shield. . : 56 63. Sogmentallining...... 7 121 333 Resistance to advance atthe face through platforms and 63.1 General see BL excavation tools. ST 632 Constructional variants voces 2122 334 Resistance to advance with slurry suppor, earth supprcand 6.3.21 Block segments with rectangular plan : 122 compressed air support...» 38 63.2.2 Hexagonal segments . 126 335 Resistance 10 advance from stering the shield 38 6323 Rhomboidal and trapezoidal segment systems 126 33.6 Summary ss... 39 63.2.4 Expanding segments .. wove BT 3.4 Empirical values for the dimensioning ofthe shield 63.2.5 Yielding lining systems Nececeeeseseee tsuneo TR and the thrust cylinders. 60 633 Jointdetals...... ad 3.5. Calculation and dimensioning basics . - 61 633.1 Longitudinal joins. fitteeesesesensnensesene ee B2 3.6 Regulations and recommendations for the design of shields e 633.2 Ring joints foes BS , ; 634 Steel fibre concrete segments ..... 2 BS 4 Excavation tools and excavation process. 8 635 Filling ofthe annular gap. oe “139 a eerie ur perry o 63.5.1 Filling with gravel..e......csscseseeeee 2139 AL Hand-held tools 6 6352 Mortar grouting... 9 412 Cutting edges ot 63.6 Measures to waterproof tunnels with segment linings 141 413 Sorapers... : 65 6361 Gaskets ial 414 Drag picks, flat chisels, round chisels, rippers 66 6362. Grouting as 4.1.5 Disc cuter, dses 6 637 Production |. ears) ALG Buckets 70 638 Damage ve 4 42. Excavation process. 2 63.81 Damage daring ring building. - sas 42.1 Tunnelling without cutting wheel .. 2 63.82 Damage while advancing the machine vas 422 Manual digging - . B 63.8.3 Damage in the shield tail seal «146 cy briceicsey ve ompenanatinigl B 63.84 Damage after leaving the shield +6 424 Mechanical full-face excavation ......2.... 8 6385 Repair of damage. 7Sew XIV___Tableof Contents ‘able of Contents XV 64 In-situ conerete lining a 147 93. Airrequirement. 641 General Ce 147 9.3.1. Determination of air requirement 642 Construction we as 93.2 Vesifcton of safety (blowout sey) 643 Concreting s ry 93.3 Special processes . 6.5 Injected concrete, Extruded concrete 149 94 Further developments 6.6 Shotorete layers asthe fia ining DIT ass Oak Compressed ar shield with unpressursed working space and. 67 Structural ealeulations .. ma 2156 full-face excavation... 214 94.2 Compressed air shield with unpressurised working spaces and 7 Shield tail sealing, grouting works. : 157 part face excavation... bese 2214 TA Shield tail seals... : wuist 943 Membrane shield a Late Ti Plastic seals : : : 138 95. Theuse of compressed air with other types of shield... 1.216 712 Steel brush seals a 160 96 Examples Laur T13 Outer shield til seals... 261 9.6.1, Old Elbe Tunnel next tothe St. Pauli landing stage, 1907 o 1911. 217 71114 Elastically sported! face Formwork for the extrusion process... 161 9.62 Energy supply tunnel under the Kiel Ford, 1989/90 219 72. Grouting process. . a 162 72.1 Requirements. wee 162 10 Slurry shields bese a . . 23 722 Conception. : one 10.1 Development histo... eesti 23 72.3 Grouting systems... we whet 10.2 Functional principle a ae 225 124 Grout : INI hes 103 Scope of application....... : 2 13. Grouting for ground improvement ae ssl 104 Machine types. ....- 228 73.1 Machinery and equipment. a he 104.1. Fullface machines with fud support. 2238 732 Groute.... : San 1042 Part face machines with slurry support os 233 733 Grouting work at the Channel Tunnel. wp 10.5 Machine and process technology : 234 10.5.1 Soil excavation L234 8 Open shields. . . ATT 10.5.2. Muck transport. . . . eee 235 8.1 Shield construction a “in 106 Examples ...... : : 237 81.1 Handshields .. ae 7 10.6.1 Westeschelde « sg3237 8.1.2 Part-face excavation Sen? 1062 Lowerln Valley alvay, Munstr"Wiesing Tunnel, main contact 8.13 Full-face excavation Casi 3-4; Jenbach/Wiesing Tunnel, main contact HB, 2007 to 2009 «243 82 Projects beens 181 10.63 Fourth bore ofthe Elbe Tunnel vo 1.247 82.1 Example: Eurotunnel —under the English Channel, 1988 to 1991 ., 181 10.64 Chongming on 2250 $22 Arrowhead Tunnel ane vec ISH 8.3. Double shields [203] ceceeee beceeeees 195 11 Earth pressure balance shields... . 83.1 Development foe pi 198 L11 Development history 832 Functional principle... figs 11.2 Funetional principle 833 Special features LI i96 11.21 Support pressure measurement and contol 833.1 Shield skin and bentonite lubrication... 196 1122 Soil conditioning... 8332 Telescopic shield ..... : Lhi96 11.2.3 Mass-volume control 8333 Examples oe TIN 113 Areas of application «...... 114 Operating modes and muck transport a 9 Compressed air shields 2.201 1141 Open mode (screw conveyor ~ conveyor bet) - 9.4 Functional principle 202 1142 Semi open mode (screw conveyor ~ conveyor belt) 9.2 Compressed air facilities 9.2.1 Air locks 11.43. Closed mode (hydraulic mucking circuit) 11.44 _ EPB mode (screw conveyor — conveyor belt or 50S SSxv us 116 2 121 122 abe ot Componer NSA ns2 1153 nsa ss Examples 116.1 11.62 1163 1.64 Convertible shields or multi mode machines. cesses Development strategies. severe 1211 12.12 Machine concepts. 12.2.1 1222 Examples 123.1 1232 I ‘Special shields and special processes. Blade shields Bad B.2 Multi-face shields B21 1322 Enlargement of shield tunnels, Pipe jacking 134.1 Pipe jacking 1342 Box jacking New concepts in mechanised shield tunnelling 135.1 B52 1353 1Bs4 B35 1356 nts Cutting wheel Bearing and drive construction Excavation chamber Screw conveyor Foam conditioning. Katzenberg Tunnel on the new railway line Karlsruhe ~ Basel, 2005 to 2007 Madrid M-30 (Bypass Sur Tunnel Nord) Heathrow : DTSS Singapore Convertible shield with integrated components for ‘multiple operating modes Building block systems Mixshield Polyshield Grauholz Tunnel, 1990 to 1993, Zirich Thalwil contract 2.01 Socatop Face support with blade shields Support types with blade shields Arrangement ofthe cutting wheels in multi-face shields « ‘Tunnel support with multi-face shields ‘Shield machines for flexible cross-sections. Ultra-flexible shield, Horizontal and vertical shield machines Enlargement shields. Rotation shields Shield docking method 152 153 154 155 16 16. 162 163 164 165 16.6 167 168 169 16.10 16.11 16.12 a 1.1 172 173 V4 175 176 117 178 18 Is. 18.2 Table of Conon Guided microtunnelling processes Pilot tube process Auger microtunnelling Shield microtunnelling English Mini Tunnel system. ‘New developments Surveying and steering Surveying : 15.1.1 Navigation with tunnel laser and automatic target unit 15.1.2 Navigation with gyroscope system and hose water level ....... 15.1.3 Navigation with total station and automatic target unt 15.14 Navigation with total station and prisms. Ring design and calculation of the ring installation sequence Ring convergence measurement. Steering Further surveying and data logging tasks Workplace safety General safety requirements. Control stations x Electrical cut-out and safety devices ania Control devices and control systems Towing connections Laser guidance Ventilation and the contol of dust and gas. Fire protection, Storage of safety equipment forthe personnel Maintenance Content of handbook Evaluation of risk in mechanised tunnelling [26]... Partnering contract models and construction ........ Introduction Requirements for the contract model Contract model according to VOB Time and cost drivers Under-pricing as a performance killer Chances and risks of partnering . Partnering ~ contractual implementation Partering ~ mutual process optimisation Process controlling and data management . Introduetion Procedur: xvll 337 338 £339 340 342 344 349 +350 351 351 355 357 359 +360 363 364 364 366 367 367 368 369 309 369 370 383 383 384 2385 386 387 22 388 2389 390 393 303 393xvlll 1s 185 186 19 19.1 192, 193 194 195 19.6 19.5.2.3 1957.1 Tal of ater Tibet coments —_X0K Target-aerual comparison 395 198 Other project conditions. a4 ‘Target process structure... sevens este eenenaaee 397 19.9 Scope of application and selection criteria 425 Analysis ofthe actual process ou — 399 19.9.1. General notes about the use ofthe tables 425 199.1.1 Core area of application. vas DAUB recommendations for the selection of tunnelling machines 401 19.9:1.2 Possible areas of application oa2s Preliminary notes 401 19.9.1.3 Critical areas of application 426 Regulatory works ae 19.9.1.4 Classification in soft ground .. 426 19.2.1 ‘National regulations 402 193.15 Classieation in rock +26 19.22 Intemational standards 403 199.2 Notes about each spe of unneling machine +426 19.23 Standards and other regulatory works ian tS) TBM cronsel Soci facta) 206 Definitions and abbreviations 1404 19.92.2 DSM (Double shield machines) 426 19.3.1 Definitions 404 19.9.2.3 SM-VI (full-face excavation, face without support) 427 19.3.2 Abbreviations. . +1406 199.24 $M-V2 (full-face excavation, face with mechanical support). 427 Application and structure ofthe recommendations “406 19925. SMLV3 (Full-tace excavation, face with compressed air Categorisation of tunnelling machines 408 application) an 195.1 Types of tumelling machine (TVM), 408 19.9.2.6 SM-V4 (ull face excavation fice with sary suppor) “an 1952 Tunnel boring machines (TBM) +408 19927 SM.NS lace excavation fae with earth presse 1952.1 ‘Tunnel boring machines without shield (Gripper TM) 408 balance support. 428 1952.2 Enlargement tunnel boring machines (ETBM) . 409 199.28 SMT (patil excavation face without suppor) “28 Tunnel boring machine with shield (TBM-S) -410 19929. SM-T2 (partial exeaaton, face wit mechanical suppor) «..-..428 19.53. Double shield machines (OSM) +410 1992.10 SM-T3 (arial excavation, face wit compressed ar application), .428 1954 Shield machines (SM) 410 199.211 SM-TS (Paral exeavaton, fe wih shy Suppor 28 19.5,4.1 Shield machines for full-face excavation (SM-V). 2410 109.2.12 KSM (Convertible shield machines) 228 195.42 Shield machines with partial face excavation (SM-T) 2413 19.10 Appendices ; 229 1955 Adaptable shield machines with convertible process technology (KSM) 44 Bibliography =i? 19.56 Special types na 1956.1 Blade shields a4 Index +463 1955.62. Shields with multiple circular cross-sections 414 19.563 Articulated shields “aid 195.7 Support and lining “45 Tonnel boring machines (TBM) ais 1957.2 Tunnel boring machines with shield (TBM-S), Shield machines (SM, DSM, KSM) «416 195.73 Advance suppor. a7 195.74 Support next tothe tunnelling machine uals Ground and system behaviour merry 196.1 Preliminary remarks 4s 19.6.2 Ground stability and face support “ais 19.63 Excavation 419 1963.1 Sticking 419 1963.2 Wear 420 1963.3 Soil conditioning 420 19.634 Soil separation. Saat1 Introduction “The mined construccion of underground infrastructure has made steady progress over recent years. Itis now possible to construct underground works with very litle impairment of buildings ot trafic flow at ground level. Particularly in inner-city areas, with sensitive infrastructure and high population density, there is an enormous demand for underground structures. The cavities created in this way have until now mostly been for underground transport routes, although there are also other possible uses such as energy extraction, storage and refuge spaces, utility tunnels and, not least, underground urban development. This fas led to extensive schemes and projects, particularly in Japan due to the very restricted space availability (Figure 1-1). Particularly in the ficld of shield tunnelling, the prominent role of Japan has been uomis- takeable. Butthe development ofthis construction method is also ata high and intemationally respected level in Germany and other parts of Europe. The shield construction process enables the production of elongated underground structures, even at shallow depths, in soil with poor Joad-bearing capacity or tinder the groundwater table, without causing any disturbance or significant settlementon the ground surface. Ground conditions with loose spherical material can be mastered, as can soft plastic or flowing soils. But the use of these machines is also. practicable in temporarily stable ground, where the shield only acts as head protectior. Allin all, shield machines ave a wide scope of application,2 1 vetction The shield construction process could but should not generally replace other methods of tunnelling, It can, however, offer a technically feasible and also economic alternative to other methods of tunnelling in unfavourable geological conditions, for long contract sections, high advance rate requirement or where stringent surface settlement limits apply. The essential advantages and disadvantages are summarised below. Advantages: — the possibility of mechanisation and high advance rate, precision of profile, = minimisation of the effect on buildings on the surface, — improved safety for the miners, environmentally friendly construction method, ~ raising of the groundwater table, = little noise, enables a high-quality and economic lining. Disadvantages: ~ long lead time for the design, production and assembly of the shield machine, long familiarisation time, ~ elaborate and expensive site facilites (a separating plant may be required); tenders may only be competitive for longer tunnel — performance risk in changeable ground, = the cross-section normally has to be round with litle possibility of variation, ~ high cost of altering the excavated geometry, e.g. for wider sections, = the lining normally has to be specially designed to resist the thrust forces. Application is therefore practicable where the advantages can be sensibly exploited and the disadvantages are taken into account as far as possible in the design and construction planning. Experience shows that a shield in the smaller diameter range can generally compete with other tunnelling methods for tunnel drives up to 2,000 m. For longer tunnels, economic applications of shield machines are possible and even cheaper than using open machines or conventional methods. The successful use of a shield always requires meticulous design and planning of the machine, the lining and the logistics. Experience and know-how are essential for a practi- cable and economic scheme. According to [235], too many clients have chosen the wrong ‘machine or construction concept for the ground conditions and have later been faced with unacceptable settlement on the surface, unexpectedly slow advance rates, spalling or fail- ure of the lining, water ingress or other defects. For the client, only a tunnel constructed ‘on schedule, of good quality and at reasonable cost, and with as little impact on the envi- ronment as possible is of interest. The designers of shield equipment need to take these natural concems into consideration. Mechanical engineering issues have to be effectively linked to those of the tunnel itself. Constant exchange of experience between mechanical and civil engineers is essential, with the appropriate evaluation of experience from com- pleted projects 1.1 Basi prnipls and tems 3 1.1 Basic principles and terms ‘The basic principle of a shield is that a generally cylindrical steel construction is driven along the tunnel axis while the ground is excavated, The steel construction supports the excavated cavity until temporary support or the final lining has been installed. The shield therefore has to resist the pressure of the surrounding ground and hold back any groundwater. While the cavity along the sides of the tunnel is supported by the shield skin itself, additional support measures will be required to support the face, depending on the ground and groundwater conditions encountered. Figure 1-2 shows five different methods of stabilising the face, which are described in detail in Chapter 2. These are: — natural support, — mechanical support, compressed air support, slurry support, — earth pressure balance support “These methods of supporting the face represent the great advantage of the shield tunnelling, process. In contrast to other methods of tunnelling, itis possible to provide immediate support of the ground as soon as itis disturbed, Inaddition tothe typeof face support, the method of excavation isan important characteristic of shields. The most simple process is manual digging in hand shields, and this is still used today in exceptional cases, for example for short sections and under certain geological conditions. Mechanical excavation is, however, more usual. This can be differentiated into mechanical partial- and full-face excavation. In partial-face excavation, the face is ‘worked in sections using machinery such as hydraulic excavators or roadheaders, which fre operated and controlled either by operators or automatically. The full face can be excavated, according to the ground conditions encountered, by open-mode wheels, rim ‘wheels (in some eases with shutters) or closed cutter heads. Further methods are hydraulic ‘excavation using pressurised jets of fluid and extrusion excavation, where the action of the thrust eylinders on highly plasti soil forces it through closable openings in the front wall of the shield, Excavation processes are described in more detail in Chapter 4 The removal of the excavated material requires special transport systems fo move the muck from the face, through the shield and to the surface. The most suitable system depends directly on the nature of the ground encountered and the associated type of face support ‘and excavation, since these factors have @ great influence on the consistency and transport properties of the muck, Figure 1-3 gives an initial overview of the possible transport systems. through the shield, which will be explained in more detail in Chapter 5. There are numerous transport methods available today, which can be categorised into the three basic groups ~ dry transport, = fhuid’slurry transport, high-density solid pumping. Transport along the tunnel can use pumped pipes, conveyor belts, dumpers or rail-based systemss 1 Invodution rama —— [support =m Cutting wee Paling plates [Mechanical E 7 support [Compressed ir support aoe Earth support por sry Mature muck! Ee Earth fing Screw comeyor Figure 1-2 Methods of supporting the ground and holding water atthe face 266) ‘The shield is pushed forward in the direction of the tunnel axis with the progress of ‘excavation in order to support the resulting cavity. The required thrust forces are produced ‘by hydraulic cylinders, normally pushing against the already installed ining, This means that the tunnel lining and boring machinery have to be finely matched. The correct function ‘of the shield and the quality of the final tunnel lining both depend on this compatibility, which is dealt with in more detail in Chapter 6 ‘The cavity produced by excavation is mostly supported with precast elements called segments. There are numerous different forms, materials, possible layouts, sealing systems and installation methods, which require detailed description (Chapter 6). Other lining systems are also possible and are already in use today (Figure 1-4). The pumping of conerete under pressure into formwork (called the extrusion process) is an interesting ‘possibility, but has not been further developed. Even shoterete can be used in connection with shield tunnelling, As the support is normally installed inside the protection ofthe shield skin, a gap remains as the shield progresses further. The gap has tobe fille in order to minimise loosening and settlement. This has to be suitably backfilled or grouted and the shield must be provided 2_Types of une! bring machine according to DAUB 5 ) 7 sj Nom enon yoo oe flpsllllll, Ypdld, \ Nowe eens ws — see secon tae ‘case using a hydraulic excavator arm) and seg sta SET ntdy Moule arenes el if mance ee, | ore ona tere a 4 cere : EE atu ecosin nd Men SE ki tong Ree ey transport, 7. Mechanica fllfae excavation transport vith a stew conveyor and transfer to a rweyor bel, 8, Extrusion excavation and transfer ofthe ‘material onto a conveyor belt Figure 1-3. Methods of muck removal in shield tunnelling Lining/Support x to (Segmental ining inate conerete| [shaw shee come Figure 1-4 Posble ype oftrng Lissteeemm | inshield tunneling 1.2 Types of tunnel boring machine according to DAUB ‘The recommendations of DAUB (the German Tunnelling Committee) are reproduced in their entirety in Chapter 19 [54]. 1.2.1. Categories of tunnelling machines German association for underground construction (TVM) ‘Tunnelling machines either excavate the full face with a cutter head or cutting whee! or part ofthe face with suitable excavation equipment. ‘These can be tunnel boring machines (TBM), double shield machines (DSM), shield ‘machines (SM) or combination machines (KSM), While the acronym “TBM” in Engish will be used for all types of tunnelling machines, the German DAUB reserves the abbreviation for the hard rock machines.6 1 rrouction ‘As the ground is excavated, the machine is pushed forward, either continuously or intermittently. A systematic categorisation of tunnelling machines is shown in Figure 1-5 (see also Ap- pendix I “Overview of tunnelling machines” in Chapter 19). 1.2.2. Tunnel boring machines (TBM) ‘Tunnel boring machines are used for driving tunnels through stable hard rock. Active support of the face is not required and, in any case, is technically impossible. These machines can normally only drive a circular cross-section, ‘Tunnel boring machines can be differentiated into those without shields (open gripper TBM), reamer or enlargement tunnel boring machines (ETBM) and shielded tunnel boring machines (TBM-S). These machines are described in detail in [203]. 1.2.2.1 Tunnel boring machines without shield (gripper TBM) (Open tunnel boring machines without shield are used in hard rock that has medium to tong stand-up time. They have no complete shield skin, Economic application can be greatly influenced and limited by the high cost of wear of the excavation tools. In order to be able to apply thrust force to the cutter head, the machine is braced radially by hydraulically driven grippers acting against the sides of the tunnel. Excavation is carried out with little damage to the surrounding rock mass and to an exact profile by dise cutters mounted on the rotating cutter head. The machine fills a large part Of the cross-section, Systematic support of the tunnel walls is normally installed behind the machine (10 to 15 m or more behind the face). In rock with a shorter stand-up time or a eT) (ee) —{bevble i tines TOSN) ee DEEDES 1.2 Types of tnnel borin machine according to DAUB 7 liable to rock falls, support measures such as steel arches, poling plates or rock bolts are installed at the closest possible distance behind the cutter head. Where shoterete lining of the tunnel is necessary, this should only be applied in the rear- ‘ward part of the backup area in order to keep the mess off the machinery and control gear in the forward machine area as far as possible. In exceptional cases, however, shoterete ‘may have to be applied as close behind the face as possible. If the geological forecast describes poor rock or a heterogeneous condition of the rock mass (high degree of jointing and fault zones), itis recommended to equip the machine to enable advance investigation drilling or advance rock consolidation, ‘The excavation of the face produces material in small pieces with the associated dust de velopment. Machines therefore require equipment for the reduction of dust development and dedusting. This can be: - spraying with water at the cutter head, — a dust shield behind the cutter head, — dust extraction with dedusting on the backup. ‘Material handling and disposal from the machine nowadays requires very long backup facilities. 1.2.2.2 Reamer tunnel boring machines (ETBM) Reamer tunnel boring machines (enlargement machines) ate used in hard rock to enlarge a previously bored pilot tunnel to the intended final diameter. The enlargement to the final diameter is performed in one or two working steps using an appropriately constructed cutter head. ‘The main elements of these machines are the cutter head, the bracing and the drive mecha- nism. The bracing of the specialised machines is situated in front of the cutter head with grippers in the pilot tunnel, and the cutter head of the machine is drawn towards the grip- pers as it bores. In faulted rock formations, measures to improve the fault zone can be carried out from the previously bored pilot tunnel in order to minimise the risks during the boring of the main tunnel. 1.2.2.3 Tunnel boring machines with single shield (TBM-S) In hard rock with a short stand-up time or liable to rock falls, shielded tunnel boring ma- chines are used. For this case, the installation of the lining within the shield is appropriate (segments, pipes ete.). While advancing, the machine can be supported from the lining, so bracing is not normally required. The remaining statements made about tunnel boring ‘machines apply accordingly. 1.2.3 Double shield machines (DSM) Double shield machines (DSM) consist of two parts arranged one behind the other. The front part is equipped with the cutter head and the main thrust cylinders, and the back part houses the auxiliary thrust cylinders and the grippers. The front part of the machine ean ee ie ee et ae La the honk mest sine @ pleannnic section,8 Inuoducton ——————————EOOOOOOOO EERE EDR EEE 12 Typesftunnel boing machine coding to DAE In stable hard rock, the gripper shoes resist the drive torque and the thrust forces. The secure fixing of the back part of the machine using the grippers enables the assembly of ‘the segmental lining in the shield tail while boring is in progress. Ina stable rock mass, it ray also be possible to omit the installation of the lining, In unstable ground, where the gripper shoes cannot find sufficient resistance, the thrust, cean be resisted from the Jast segment ring, The front and back parts of the machine are retracted ‘ogether and the thrust forces are pushed from the segment ring by the auxiliary thrust cylinders. Itis not normally possible to actively support the face or the sides of the excavation, Due to the rapid advance of the back part of the machine after a boring stroke has been ‘completed and the grippers are being regripped, the rock mass has to be able to stand up independently until the annular gap has been completely filled with grout or stowed with pea gravel. 1.2.4 Shield machines (SM) ‘These can be shield machines with full-face excavation (with a cutter head: SM-V) and shield machines with partinl-face excavation (using a roadheader boom, excavator: SMT), Shield machines are used in loose ground above and below the groundwater table. This normally means that the ground around the cavity and at the face has to be supported. Shield machines can be further divided according to the type of face support (Figure 1-5). 1.2.4.1 Shield machines with full-face excavation (SM-V) 1) Face without support (SM-V1) Ifthe face will stand up, e.g. in clay soil with stiff consistency and sufficient cohesion or in solid rack, open shields can be used, The cutting wheel fitted with tools excavates the soil and the muck is removed on a conveyor belt. In solid rock liable to rock falls, shield machines with a mostly closed cutter head fitted with dise cutters and fully protected from the unstable ground by a shield skin are nor mally used. The thrust forces and the cutter head drive torque are transferred through the thrust cylinders to the last ring of segments installed. 2) Face with mechanical support (SM-V2) ‘With tunnelling machines with mechanical support, the support of the face during exeava- tion is provided by elastically fixed support plates arranged in the openings of the cutting ‘wheel. In practice, however, experience shows that that no appreciable mechanical sup- port ofthe face can be provided by the rotating cutting wheel. For this reason, this type of cutting wheel did not prove successful in unstable ground and is no longer in use today. The mechanical face support by the cutting wheel or the support plates should only be considered a supplementary safety measure and the supporting effect should not be taken {nto account in calculations to verify the stability of the face, 3) Face with compressed air support (SM-V3) Shield machines of type SM-V3 can be used below the groundwater table even if it eannot be lowered or groundwater lowering is not allowed. In this case, the water atthe face must bbe held back with compressed ait. A precondition for the displacement of the groundwater is the formation of an air flow to the surface. Impermeable strata above the tunnelling machine can retain the applied air and prevent the effective displacement of the water (and thus the formation of an air flow). The permeability limit of the surrounding ground is therefore significant. |AS no pressure difference can be built up at the face, compressed air cannot generally provide support against earth pressure, which applies particularly in permeable soil. The Joss of the apparent cohesion in non-saturated soil is also possible. For the duration of tunnelling work, either the entire tunnel is pressurised or the machine is provided with a pressure bulkhead to maintain the excavation chamber under pressure. In both cases, air locks are required. Particular attention needs to be paid to compressed. air bypassing the shield tail seal and the lining. The recommendations and requirements for working under compressed air should complied with. Any additional support of the face provided by the cutting whee! or support plates should be regarded solely as an additional security. It is not permissible to take the supporting effect into account in calculations to verify the stability of the face. 4) Face with slurry support (SM-V4) Tunnelling machines with sturry support provide support tothe face through a pressurised fluid whichis specified depending on the permeability ofthe surrounding ground. It must be possible to vary the density and viscosity of the fluid. Bentonite suspensions have proved particularly successful for this purpose. In order to support the face, the working ‘chamber i elosed from the tunnel by a pressure bulkhead The required support pressure can be regulated very precisely with an air bubble behind a submerged wall and by adjusting the output of the supply and extraction pumps. The required and the maximum support pressures over the entire length to be bored should be calculated before the start of tunnelling ~ referred to as the slurry support pressure calculation, The soil is excavated from the full face by a cutting wheel fitted with tools (open-mode or rimmed wheel) and removed hydraulically. Subsequent separation of the removed suspension is essential If it is necessary to enter the excavation chamber, for example to change tools, carry ut repair work or to remove obstructions, the support slurry has to be replaced by compressed air. The support slurry then forms a low-permeability membrane on the face, which however is of limited durability (risk of drying out). The membrane permits the support of the face by compressed air and may need to be renewed regularly. The support slurry can be completely (empty) or only partially (lowering) replaced by compressed air. The maximum partial lowering is limited particularly by the requirement for sufficient working space. This should be chosen to be large enough for safe working to be possible: