AFTES

GUIDELINES ON

CONSTRUCTION TIME ANALYSIS AND COEFFICIENT

OF UTILISATION OF TUNNEL BORING MACHINES
AFTES welcomes comments on this article

Version 1 – 1998 - Approved by Technical Committee 7 April 1998

Text prsented by
Pierre LONGCHAMP, BOUYGUES, animateur and
André SCHWENZFEIER, CETU, vice-Chairman of Working Group 4 Mechanisation of Excavation
With contributions from :
Laurent CHANTRON - CETU - Pierre BOUTIGNY, CAMPENON BERNARD - SGE - Jean-Claude DAUMARIE, SNCF
Jean Marie DEMORIEUX, SETEC - Jean-Louis GIAFFERI, EDF - Jean-Marc FREDET, SIMECSOL - Fabien MAUROY, SOFRETU
Yvonnick RESCAMP, DG Construction - Jean Marie ROGEZ, SOFRETU - Jean François ROUBINET, GTM
AFTES Editorial Committee
Jaques CHEZE, SIAAP

CONTENTS

Pages Pages
FOREWORD 184 6 - DATA MANIPULATION 186

1 - RECOMMENDATIONS PRE-DATING THE 185 7 - CONCLUSION 187

PRESENT GUIDELINES
ANNEXES : Exemple : typical shift report form 188
2 - CONVENTIONS 185 Exemple : results presentation 189
3 - OPERATING TIME ANALYSIS 185 Exemples :
LILLE METRO - Line 2 Contract 2 190
4 - DEFINITION OF COEFFICIENTS 186
APPLICATION TO LYON METRO 195
5 - DATA COLLECTION AND COMPILATION 186 LINE D EXTENSION (VAISE TO GORGE DE LOUP)

FOREWORD
The July/August 1976 issue (No. 16) of
Tunnels et Ouvrages Souterrains featured
proposals drafted by AFTES Working Group
4 on the definition and application of a num-
ber of coefficients and indices aimed at stan-
dardising, for the purposes of comparison
between different tunnelling jobs, concepts
which had been nearly inexistent up to that
time, for analysing the time actually spent on
the construction of machine-driven tunnels:
these were coefficients of utilisation, availabi-
lity and downtime, and indices of reliability
and full-use.
These proposals, repeated in the TOS 1982
special issue, mainly concerned hard ground
TBMs which had been undergoing conside-
rable development worldwide in the early
nineteen-seventies.
In the same period, the newly-created AFTES
association was investigating the experience
and ideas of TBM users and their need for
unifying their terminology, performance moni-
toring and analytical methods.
The first proposals on standardised coeffi-
cients were generally welcomed by the engi-
neering community and completed record
forms from many jobsites were forwarded to
AFTES to create and update a useful database
of “Records of Mechanised Tunnelling Jobs,
1996 Survey.”
The objective now is to attempt to establish a
single, consistent general method for collec-
ting and collating tunnelling performance data
by means of these proposed Guidelines.

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 Construction time analysis and coefficient of utilisation of tunnel boring machines
1 - RECOMMENDATIONS
PRE-DATING THE PRESENT
GUIDELINES
1.1 - The earlier recommendations concer-
ned the following coefficients and indices:
- Coefficient of utilisation “alpha”: TBM
working time/total duration of productive
shifts (%)
α = 100 M/T
- Coefficient of operational availability “beta”:
time during which the TBM is in operational
condition/total duration of productive shifts (%)
β = 100 (T-P)/T
- Reliability index “phi”: operating time/opera-
ting time + downtime.
ϕ = 100 M/(M+P)
- Full-use index (or simplicity index) “gamma”:
coefficient of utilisation / coefficient of
availability
γ = α/β
- Standby coefficient “delta”: coefficient of availa-
bility– coefficient of utilisation (%)
δ=β−α
1.2 - These coefficients and indices refer-
red mainly to rock tunnelling machines, practi-
cally the only type used in France at the time.
It was not until 1983 that closed-face shields
began to come into common use in France,
partially due to the Tunnels 85-90 national
research programme.
Note. Working time, previously denoted M,
will henceforth be denoted F.
2 - CONVENTIONS
2.1 - A TBM or tunnel boring machine
consists of the excavating machinery, shield
and tailskin, and associated back-up attached
to, and advancing with the shield.
2.2 - – Logistics support equipment com-
prises loco track, mucking train, etc., surface
set-up, shaft mucking equipment, spoil treat-
ment station, handling equipment, pipework,
etc.
2.3 - The work cycle is a series of tasks lea-
ding to the construction of a unit length of
tunnel, involving permanent lining ring or tem-
porary support, stroke, etc.
Cycle length (c) is expressed in metres.
2.4 - TBM operating time (F), expressed in
minutes, is the algebraic sum of the following
task times, some of which may be zero:
TUNNELS ET OUVRAGES SOUTERRAINS – HORS-SERIE N° 1 – 2005
(E) Excavation
(R) Lining or temporary support
(G) Regripping
(S) Simultaneity (overlap) of above
(J) Inevitable tasks
(E), (R) and (G) are total times and (S) is the
overlap between these three.
F=E+R+G-S+J
TBM operating time (F) is the critical time for
completing a cycle excluding breakdowns and
standby times.
Notes
a) It is not always possible for items (E) and
(R) to overlap (S). It is possible for example
on shields with telescoping heads (cutterw-
heel or boom).
Systematic placement of support immediately
behind the shield in rock tunnelling may also
allow simultaneity.
b) Regripping (G) is considered for example
as comprising the following:
- Moving the grippers against the rock
- Resetting a telescoping machine.
If regripping time is very short, it is included in
(E) or (R).
c) The four terms (E), (R), (G) and (S) do not
in fact add up to the total operating time.
There are frequently certain “inevitable tasks”
(J), the time for which lies on the critical path.
Such tasks are systematic interruptions to the
drive that are essential for tunnelling to pro-
ceed: part of the time needed for back-grou-
ting the lining, laying more track, periodically
lengthening cables and pipework, surveying,
etc.
These tasks may be considered as part of the
normal operating cycle. They must be preci-
sely described for each job.
d) Particular features of some machines may
call for amending these conventions and must
be described in detail in the remarks accom-
panying the operating time analysis.
2.5 - The MEAN OPERATING TIME PER
CYCLE (f) is, for a given period T, the ratio
between operating time F and the number of
cycles n completed over period T:
f = F/n
2.6 - – The UNIT SPEED Vu in centimetres
per minute is the ratio between cycle length
(in metres) and mean operating time per
cycle f (in minutes):
Vu = 100 c/f
• 185 •
3 - OPERATING TIME
ANALYSIS
3.1 - has its own technological and organi-
sational features and Contractors and
Engineers have their own viewpoints as
regards their separate management goals.
These draft Guidelines are therefore based
on simplifying assumptions and conventions,
in theory valid for all mechanised tunnelling
jobs (except microtunnelling). They provide
a general framework which individual users
must develop, detail and adapt to their own
particular circumstances.
3.2 - – Continual time analysis on a mecha-
nised tunnelling job offers a means of deter-
mining the time taken for each of the tasks
lying on the critical path, in order to
a) compare actual progress with the basic
design assumptions and identify changes and
trends,
b) understand special events and the overall
progress of the job,
c) conduct an efficient spare parts policy and
maintenance planning,
d) detect repeated anomalies and abnormally
weak points in the tunnel driving process,
e) propose corrective action and monitor its
effect,
f) build up a database associated with AFTES
jobsite record forms.
3.3 - All periods can be analysed:
- Construction time for a lining ring or series
of rings
- Shifts
- Days, weeks, months
- Total tunnel construction time.
For example, time T may or may not include
- TBM start-up time before the machine is
equipped with all its back-up parts
- excavating station chambers.
3.4 - Time (T) called total worked time is
the sum of at least eight critical times, some of
which may be zero:
(F) TBM operating time
(P) Downtime due to TBM breakdowns
(M) TBM maintenance
- (M) comprises two terms, Mp and Mnp to
distinguish between planned maintenance
(Mp) and unplanned maintenance ( (Mnp):
(M) = Mp + Mnp
- Mp represents planned maintenance tasks
and time allowed for the work
(K) TBM standby time due to breakdowns in
other items
 Construction time analysis and coefficient of utilisation of tunnel boring machines
(H) Planned maintenance and stoppages of
items other than the TBM
(A) Standby time due to site organisation or
interruptions in the sequence of productive
tasks for reasons other than breakdowns
(X) Explorator y work ahead of the face
(probe drilling) requiring TBM stoppage
(I) Sundry other stoppages not included in
the above.
Note
(Mp) and (Mnp) can themselves be broken
down into several components (Mp1, Mp2,
Mnp1, Mnp2, etc.).
Such a breakdown may distinguish between
maintenance of parts not in contact with the
ground and parts directly in contact with it
(cutting tools, screw conveyor, pumps, etc.).
4 - DEFINITION OF
COEFFICIENTS
The only coefficients and indices from the
1976-1992 AFTES recommendations retai-
ned here are the coefficients of TBM utilisa-
tion and reliability, as being the only ones rele-
vant to the time analysis models.
The full-use index and idle time coefficient
derived from these two are no longer the
subject of any special recommendations
because experience has shown them to be of
only minor interest.
Coefficient of utilisation
Is the percent time the TBM operates over
the total time worked.
This is the same definition as before but the
coefficient is now written U instead of α:
U = 100 F/T
Field coefficient of availability
Is the time for which the TBM could theoreti-
cally have worked if there had been no stop-
pages, as a percentage of total worked time.
The coefficient of availability is now written D
instead of b. It covers all events that might
arise on the job.
D = 100 (T-P)/T
Breakdown rate
Is the reciprocal of the coefficient of availabi-
lity. It is the time the TBM is idle through
breakdowns as a percentage of total time
worked.
This coefficient is written W.
W = 100 P/T
(D + W = 100%)
TUNNELS ET OUVRAGES SOUTERRAINS – HORS-SERIE N° 1 – 2005
Note
In contractor/manufacturer relations, one
uses the the design coefficient of availa-
bility (Dm).
Dm is the TBM operating time over TBM pro-
duction time Tp = F+ P + Mnp.
Dm = 100 F/Tp = 100 F/(F+P+Mnp)
5 - DATA COLLECTION AND
COMPILATION
5.1 - Time data must be collected conti-
nuously from the start of the job, during all
working shifts.
Times are in principle recorded to the nea-
rest five minutes or, in some cases, one minute
for tasks that, although short in themselves,
cumulate and significantly affect critical cycle
times.
This does not determine the precision of the
analysis as a whole, which can never achieve
such detail.
The Contractor's SHIFT REPORT provides
the basic input for time analysis.
The shift report is in fact a set of forms, each
concerning a type of data: elapsed time and
incidents, TBM operating parameters, lining
ring monitoring forms, surveying, etc.
Although these records are kept mainly for
the Contractor's purposes, the shift report
must include all information considered rea-
sonably useful to the Engineer.
The data may usefully be cross-checked
against the data acquisition system for para-
meters such as E, R and G.
It is therefore necessary on tunnelling jobs to
institute a contractual relationship between
Engineer and Contractor in the matter of
data collection and compilation.
The relationship must be clearly and compre-
hensively described in the Contract. It might
result in an integrated management model for
all physical parameters relevant to the job.
Reporting may take several forms: annotated
bar charts showing the critical path for indivi-
dual cycles, chronological list of tasks, with or
without graphs. It is a subjective decision and
rules cannot be laid down, but use of the typi-
cal shift repor t form presented here is
recommended. When building small, shor t
tunnels (e.g. sewers) with limited resources, a
simplified system of data recording might be
appropriate.
• 186 •
5.2 - Each major activity or repetitive task
on a machine-driven tunnelling job must be
assigned a logical code number.
Breakdowns and other incidents are conside-
red as activities in the same way as strictly
productive tasks. More code numbers are
added as the job progresses and new activi-
ties occur.
6 - DATA MANIPULATION
Systematic real-time analysis of the coded
progress repor ts produces the following
items.
6.1 - Daily, weekly, monthly and other SUM-
MARY TABLES presented in a logical order
highlighting critical times.
• Operation (F) broken down into terms (E),
(R), (G) and (J)
• TBM breakdowns (P)
• TBM maintenance (M)
• Other stoppages (K)
• Other maintenance (H)
• Stand-by time (A)
• Exploratory probing (X)
• Miscellaneous (I).
Some of these parameters (e.g. H or X) may
not be applicable and may be ignored.
Calculated values of U and D are shown,
along with certain results characteristic of the
periods analysed (driven length, mean pene-
tration rate, mean cycle time).
6.2 - DETAIL FORMS on downtime and
standby time classified into coded activity
units, thrust systems, lining erection equip-
ment, main conveyor, mucking train break-
downs, logistics support installations, standby
due to electricity supply, cleaning, etc.
6.3 - GRAPHICS illustrating trends in the
times, and comparing them with expected
targets.
• Histograms of parameters analysed (exca-
vation time, lining times, simultaneity, break-
downs, etc.) and calculated values (coeffi-
cients U and D, mean operating time per
cycle f, unit speed Vu, etc.)
• Activity performance times (excavation,
support or lining, stoppage, etc.) per linear
metre, for comparison with other projects
 Construction time analysis and coefficient of utilisation of tunnel boring machines

• Pie charts showing proportions of different TASKS, FUNCTIONS, ACTIVITIES UNITES RELATIONS
functions or activities over a stated period.
1. OVERALL TIME VALUES
F TBM operating time min F=E+R+G–S+J
E Excavation min
7 - CONCLUSION R Lining or support min
Time analysis is the basis for performance G Regripping min
monitoring and works management in any S Simultaneity between functions E, R and G min
mechanised tunnelling job. J Inevitable tasks min
P TBM breakdowns min
It determines prospects for change, identifies
M TBM maintenance min
oppor tunities for amelioration or amend-
Mp TBM planned maintenance min
ment, underpins efficient spare stock manage-
Mnp TBM unplanned maintenance min M = Mp + Mnp
ment and maintenance planning.
K Non-TBM breakdowns min
Viewed beside other impor tant data (e.g. H Non-TBM planned maintenance and stoppages min
TBM physical operating parameters), it may A Standby time min
lead to a management aid for maximising effi- X Time for probing ahead of face min
ciency, time and possibly cost performance. I Sundry other stoppages min
It is also the basis for compiling a trustworthy, T Period of analysis min T = F+P+M+K+H+A+X+I
expandable database to be used in future Tp TBM production time min Tp = F+P+Mnp
project design work.
2. COEFFICIENTS
U TBM coefficient of utilisation % U = 100 F/T
D TBM field coefficient of availability % D = 100 (T-P)/T
W TBM breakdown rate % W = 100 P/T
(D + W = 100 %)
Dm TBM design coefficient of availability % Dm = 100 F/Tp

3. LENGTHS & CYCLES

L Final tunnel length m
I Tunnel length driven in period m I = nc
c Cycle length m
N Number of cycles to final tunnel length — N = L/c
n Number of cycles completed in period — n = l/c

4. MEAN TIME PER CYCLE

f Mean operating time min f = F/n
e Excavation min
r Lining & support min
g Regripping min
s Overlap (simultaneity of e, r, g) min
j Inevitable tasks min
p TBM breakdowns min
m TBM maintenance min
mp TBM planned maintenance min
mnp TBM unplanned maintenance min m = mp + mnp
k Logistics support equipment breakdown min
h Logistics support equipment maintenance min
a Standby time min
x Exploratory probing min
i Other stoppages min
t Mean cycle time min t = T/n

5. MEAN VALUES
lj Mean length per day m/day
lm Mean length per month m/month
Tu Unit time min/m Tu = f/c
Vu Unit speed cm/min Vu = 1/Tu = 100 c/f

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 TYPICAL SHIFT REPORT FORM

SHIFT REPORT
TUNNELLING

MORNING AFTERNOON NIGHT

Written by Checked by Shift foreman :

EXCAVATION
SUPPORT/LINING
TBM SUPPORT
T. INEVITABLES

TBM BREAKDOWN

• 188 •
MAINTENANCE

OTHER BREAK-

TUNNELS ET OUVRAGES SOUTERRAINS – HORS-SERIE N° 1 – 2005

OTHER MAINTENANCE

STANDBY

PROBING
Construction time analysis and coefficient of utilisation of tunnel boring machines

MISC

REMARKS
 Construction time analysis and coefficient of utilisation of tunnel boring machines

SUMMARY FORM

JOB NAME – SECTION

Number of shifts PERIOD OF ANALYSIS

Total length of section
Driven length for analysis
Progress (m/day)
Progress (m/shift)
Number of lining rings/length *

TBM characteristic parameters

U Coefficient of utilisation
EXEMPLE DE PRESENTATION DES RESULTATS

D Coefficient of availability
Dm Design coefficient of availability
W Breakdown rate
Vu Unit speed (cm/min)

Mean time for completing section OPERATING TIME

Excavation (E)
Lining/support (R)
Inevitable tasks (J)
TBM operating time(F) *
TBM breakdown (P)
Maintenance (M)
Other breakdowns (K)
Other maintenance (H)
Standby (A)
Probing (X)
Sundry (I)
Tunnelling, complete (T)

TBM BREAKDOWNS BACK-UP BREAKDOWNS

** **

*Necessary
** Optional

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 Construction time analysis and coefficient of utilisation of tunnel boring machines

LILLE METRO
Line 2 Contract 2
Driven length 3962m – Driven diameter 7.72m

METHOD OF TUNNEL The analysis period runs M. Maintenance (maintenance generally

CONSTRUCTION TIME
ANALYSIS
In line with AFTES recommendations, the
time analysis for this project was conducted
on the basis of tunnel sections between sta-
tions as follows:
Entry shaft at Sebastopol station
Sébastopol-Tourcoing Centre
Tourcoing Centre-Colbert
Colbert-Phalempins
Phalempins-Pont deNeuville
Pont de Neuville-Bourgogne
Bourgogne-CH Dron.
The time analysis for these six sections does
not include for entry from stations, entry into,
and passage through stations, and stoppages
to dismantle reaction structures (frame and
temporary segments) at stations.
(Voir fiche technique n° 72 à la fin de la présente revue.)
• from start of activity analysed at the TBM
stroke in which the first lining ring was erec-
ted after leaving the station
• to completion of activity analysed at the
final stroke when contact was made with the
diaphragm wall of the station to be crossed.
Therefore the summar y form shows two
lengths:
• tunnel length between stations (between
station boundaries)
• tunnel length for time analysis.
The box below shows the abbreviations for
tasks, problems, breakdowns, standby periods
and stoppages entering into the analysis and
their breakdown into the following terms:
F. comprises Excavation, Lining and inevi-
table tasks
P. TBM breakdowns
K. Other breakdowns
performed on Saturdays does not
enter into the analysis)
A. Standby times
I. Sundry stoppages.
Two mean penetration rates appear on the
summary form:
- daily progress
- progress per shift.
These two are needed on this job because
some tunnel sections were driven on a two-
shift basis (from entr y shaft to Tourcoing
Centre station), then in three shifts to the end
of the contract.
Mean times for excavating, lining and support,
and inevitable tasks are expressed in running
metres for comparison with mean construc-
tion time per metre incorporating critical
times.

ABBREVIATIONS USED ON JOB FOR TIME ANALYSIS

INEVITABLE TASKS J Kts Servce train breakdown

Jto Survey/Measurement Kd Service train derailed
Jr Lay rail Mortar
Jve Telescope ventube Kme Mortar mixer
Jmt Telescope electric cable Kms Mortar delivery (Secatol skip)
Admixtures
TBM BREAKDOWNS P Km Foaming agent problem
Pe Electrical problem Ke Water injection problem
Ph Hydraulics (incl. disk & overcut)
Pv Screw breakdown STANDBY A
Per Erector breakdown Ats Awaiting service train/segment loading
Pmo Monorail/trolley/picker/table breakdown Apr Awaiting deliveries (bentonite; foaming
agent, etc.)
Pi IT breakdown (CAP, automation)
An Clean tailskin
Pt Belt/Conveyor/hopper R5 breakdown
Am Waiting on weather (frost, storm, etc.)
Pj Gasket problem
Av Awaiting track fixing, points, etc.
Pa Articulation problem
Ato Abnormal survey results
Ps Jack problem Ad Sundry causes
Pr Trucks derailed
Pm Miscellaneous MAINTENANCE M
Mn Clean tunnel
OTHER BREAKDOWNS K Mr Shift change & training
Handling gear
Kp Portal crane SUNDRY STOPPAGES I
Kg Crane Ie Environment (strike, noise, fire, etc.)
Kb Spoil sticking in mucking cars Io Obstacles in tunnel (loco, men, etc.)
Kl Loco breakdown

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 Construction time analysis and coefficient of utilisation of tunnel boring machines

SUMMARY FORM
Interstation PHALEMPINS-PONT DE NEUVILLE

Number of shifts
Total length of section
Driven length for analysis
Progress (m/day)
Progress (m/shift)
Number of lining rings (1.25 & 0.80)

U Coefficient of utilisation
D Coefficient of availability
Dm Design coefficient of availability
W Breakdown rate
Vu Unit speed (cm/min)

Excavation (E)
Lining/support (R)
Inevitable tasks (J)
TBM operating time(F)
TBM breakdown (P)
Maintenance (M)
Other breakdowns (K)
Other maintenance (H)
Standby (A)
Probing (X)
Sundry (I)
Tunnelling, complete (T)

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Construction time analysis and coefficient of utilisation of tunnel boring machines

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Construction time analysis and coefficient of utilisation of tunnel boring machines
Construction time analysis and coefficient of utilisation of tunnel boring machines
 Construction time analysis and coefficient of utilisation of tunnel boring machines

APPLICATION TO
LYON METRO
LINE D EXTENSION (VAISE TO GORGE DE LOUP)
Track 2 Section 2 (Valmy to Gorge de Loup)
Length 335m

FOREWORD K1 : Waiting slurry delivery or breakdowns at

Unit times are calculated with data from the
shift reports (3 shifts per day, five day week)
kept by the Contractor in 1994, to within five
minutes for each of the tasks specified.
There are fewer tasks specified on the shift
repor ts than recommended by the new
Guidelines, and special rules had to be intro-
duced to apply them to the Vaise slurry shield
job.
As a general rule, where operations overlap,
the key activity in TBM operation is recorded
in the shift report order.
OVERALL TIME VALUES
P - TBM breakdowns
P = P1 + P2
P1: Electrical faults
P2: Mechanical faults
We only consider breakdowns affecting the
TBM and equipment towed by it (excl. Sotres
unit).
M - TBM maintenance
This covers all work under pressure in the
working chamber to ensure optimum TBM
performance (face inspection, head inspec-
tion, maintenance). Except if otherwise stated,
this is unplanned maintenance (Mnp).
the slurry pump
K2 : Breakdowns or standby at spoil-separa-
tion and slurry preparation station.
Note
Operating a by-pass mucking method after
driving a ring must not be considered as a K2
breakdown.
I - Miscellaneous stoppages
Times not included in the above parameters
and not specified on the shift report form.
APPLICATION

A - Standby times 1 - Complete 335m drive, lasting 14,869

F- TBM operating time five-minute units
Those are generally waiting times for lining
F=E+R+G-S+J segment delivery. 2 - Ignoring entry, 329 metres, lasting
E: Excavation including back grouting lining 13,525 five-minute units
R: Installation of 1-metre lining ring K - Duration of breakdown for
G: 0 equipments other than the TBM
S: 0 K : K1 + K2
J: J1 + J2 + J3 + J4 inevitable tasks
J1: Lay track
U D W Dm νmax νmean
J2: Extend mucking ducts
J3: Extend pipes and cables 335 m 42.1 % 96.6 % 3.4 % 81.5 % 14 m/day 6.60 m/day
J4: Survey 329 m 44.9 % 96.3 % 3.7 % 81 % 14 m/day 7.00 m/day

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Construction time analysis and coefficient of utilisation of tunnel boring machines

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METRO DE LYON - LIGNE D - TRONÇON VALMY - GORGE DE LOUP/ VOIE 2 Construction time analysis and coefficient of utilisation of tunnel boring machines
Tableau des temps unitaires (1 unité = 5 mn)

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 Construction time analysis and coefficient of utilisation of tunnel boring machines

METRO DE LYON - LIGNE D - TRONÇON VALMY - GORGE DE LOUP/ VOIE 2

Tableau des temps unitaires (1 unité = 5 mn)

TUNNELS ET OUVRAGES SOUTERRAINS – HORS-SERIE N° 1 – 2005

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