TUNNEL MANAGEMENT PROCESS

DESIGN INPUT / Tunnel Purpose FUNCTION

ALIGNMENT OF RAIL
GEOLOGICAL -GEOTECHNICAL MODEL
TRACK & STATION
SITE INVESTIGATIONS (All previous data, desk
CONFIRM LOCATION, shafts etc
study, other project data.)
ALIGNMENT - Design
modifiaction may be
necessary, signalling,
route restrictions, DESIGN PROCESS
BUILDING CONDITION SURVEYS, SURVEYS FOR UTILITIES, ID NATURE
internal lining STRUCTURAL SURVEYS, OF MATERIAL & ALLOWABLE LIMITS Segment / Linimg
TBM Design OF DEFORMATION Design

SETTLEMENT ANALYSIS BUILDING RISK ASSESSMENTS & IDENTIFY & DESIGN SITE INVESTIGATIONS
Ground loss, shield loss, tailskin PROTECTION PLANS. Allowable Limits PROTECTION WORKS Supplementary & Instrumentation
loss, sensitivity of Deformation Installation

factors into design

TBM OPERATIONAL PARAMETERS & INSTRUMENTATION GEOLOGICAL PROFILE & GEOTECHNICAL
RANGE -Face Pressure, grout pressure/volume
&/or correction
DESIGN / PARAMETERS
MONITORING REGIME Input 'field data'

FORM & FINISH Confirm or Revise Building protection

Works as required. Revise risk assessment

DESIGN OF TUNNEL ADVANCE

Horizontal & Vertical Alignment - deeper tunnels have greater pressures, tight curves may require tapered rings
DESIGN OUTPUT Geotechnical Interpretation - possible geological hazards, mixed face conditions, geological boundaries
Face Pressures - control of face pressure to avoid stress relaxation & overexcavation
Weights / Volumes - assessment of weight based on range of in-situ density, assess likely use of soil conditioning
Instrument Plan - types & distribution of instruments based on predicted settlements and location of buildings, frequency of reading
Settlement Contours & Settlement Limits - assessment of extent of predicted settlement, allows a check to be carried out during Confirm /Reassess Geological profile and
CONSTRUCTION INPUT construction face pressures required to ensure settlements
Required Consolidation Works - building protection worked to prevent any adverse effects due to settlement. controlled.
High Risk Areas, Structures & utilities- indicated on drawings to advise of additional care/reporting
Anticipated Anomalies & Actions - Loss of face pressure, additional grout, overexcavation
ALIGNMENT Probing - predicted geology, Rates of penetration
VERIFICATION - Track Work
Validation / hydraulics and
falls

coorections CONSTRUCTION PROCESS

built,
CONSTRUCTION MONITORING
survey / as-
N - Wriggle Tunnelling Confirm Extent and magnitude of
VALIDATIO TBM Parameters settlement, correctness of face pressure
Face Pressure
ALIGNMENT TBM Operation Grout Volume & Pressure
Face pressure, Muck Volume
Grouting Volume & Pressure TBM - GROUND INTERACTION Thrust, torque & Advance Speed
Muck Volume Compliance with settlement limits
Thrust Compliance with Face Pressure & Grout Instrumentation
requirements Drilling Data against geological profile
Torque Planned against actual settlement
Speed of Advance Compliance with alignment Monitoring of Treated Areas
Steering / Survey Control DAILY/WEEKLY BASIS REVIEW OF DATA
Immediate Actions
Lining Erection Reading Frequency FEEDBACK
Build Quality / Repairs Accuracy checks
Visual Inspections of surface/buildings
Alignment

Ground Treatment
Drilling
Grouting
Verification

Immediate Actions
Alarm Plans
Standard Operating Procedures
Emergency Plans
SAFE TUNNELLING

Controlled settlement, minimal impact on

infrastructure, optimised face pressures,
controlled progress, FUNCTIONALITY
VERIFIED
CONSTRUCTION OUTPUT
TBM/Tunnel Aide Memoire (MP - 2002)

DESIGN / PLANNING TUNNEL GEOLOGY ROUTE RISKS / SAFETY TBM DESIGN LINING DESIGN SHAFT/PORTAL DESIGN MUCK DISPOSAL

Personnel - trained, Purpose. Sizing for Site Investigation Land use, rights, mineral rights, Fire Loads, water pressure, TBM weight, Loads, geometry, eccentric Temporary use. Types
experienced. Geology, permananet and (Construction check, probing, future use and poss effcets on cutterhead, bearing seals, tail seals. loads, handling, no of segments, (suitable/unsuitable)
geotechnical, mechanical, temporary equipment additional SI, instrumenattion tunnel. Tunnel Protection. Comp. Air. Max sizes/loads for tpt tolerance on dimension,
civil, structural, tunnel. plus future expansion.. BHs, muck, face logs, shaft assembly. lips/steps
holes etc)
Design Statement Size Desk Study Portals & Shafts Flood Jack propulsion & no. TBM interaction Final use, Volumes
Risk assessment Route and land Engineering Properties. Needs Construction requirements Explosion Shield length & minimum radius, Accessories - bolts, gaskets, Loads, dimensions, Uses
acquisition plus future for ground improvement articulation dowels, packing instruments
development and current
u/gnd works
Interfaces and interface Time/cost estimates Water Pressure Depth Collapse Screw size & capacity, mucking E&M equipment, Trackwork Strut /access arrangements. Disposal areas
management system, volume/weight control
(density/flow)
Programme, programme Method(s) of Abrasivity, mixed face Gradients Portals & Shafts Grouting (tailskin), back-up, soil Strength, permeability, TBM installation loads Storage Areas
compatability and construction + pros/cons conditions, hazards. Squeezing conditioning. Replaceable brushes. durability, drainage, dimensions. Thrust frame
availability of and risks ground. waterproofing capacity.
data/personnel.
Tender documents and Lining (one pass, two Reqm'nts during construction. Speeds/velocities Access Segment design & handling system. Cross passages, station Interface wrt water, Contractors & policing,
tender evalaution. stage etc). interfaces differential movement. docket system.
TBM Procurement, Depth & flotation Seismicity, landslides, Buildings & sensitivity. Risk Register & assessments Guidance system & Data logger. Fire Required curvature, Tapers, Transport - type, ID, GPS
novation, supplied,etc flooding. Pot/sink holes, faults plus mitigation & ownership suppression packing control.
Geotechnical Requirement for cubbies Previous land use, Ventilation shafts Ventilation , temprature, Human factors, access, safety Mix design/steel reqmnts.
Interpretative report and cross passages. contamination, mining humidity, face and tunnel
CONSTRUCTION SURFACE WORKS TBM SEGMENTS TUNNEL BACK-UP FACILITY MUCKING GROUTING SETTLEMENT
Personnel - trained, Layout & Location Delivery route re loadings, Casting yard, moulds, vibration, Personnel access delineated Hydraulics, Soil conditioning, tail Muck quantity (vol/wght), type Tailskin grouting, back Extent & magnitude.
equipped, shifts, PPE, widths, clearances, insurance curing, lifting, storage. Site from locos. Man-riders grease, power packs, water (geology)), suitability grouting. Equipment, Confirm prediction.
induction courses Delivery/Inspections tanks/lines, grout tanks/lines, (conditioning) maintenance. Duty/standby.
transformers. Operator cabin
Risk assessments in line Drainage Insurance during transport. Concrete strength & testing. Equipment & cables/pipes Access, lighting, comms, first aid Screw speed/discharge Mix design & volumes. Instruments, type,
with BS6164, loaction, reading
frequency.
Programme and Hoarding & Gates Delivery / assembly times Accessories & supply Points and cross-overs + Guidance system, survey control Conveyors (moving) Gel / set time & strength In ground instrumnets,
programme compatability. signals through TBM. gain. buildings, temp. works.
Interfaces ID'd & risk
areas.
Time and cost, earned Lighting Assembly areas. Workshops. Repair procedures, gasket Capacity of loco/train. Evacuation routes, procedures. Rail movements & Health & safety ref Risk analyses, back
value curves, rates of repair. Braking, Derailments Emergency lights. Fire points & signaling.Capacity of train /loco accelerators cement . analysis. Real time data.
production suppression/smoke curtain. braking.

Procurement - TBM, Signage Sequence of Rates of production/delivery. Runaways, signals/alarms, Storage, cleaning & maintenance Muck handling in pit bottom, Drilling capability for probing, Surface inspections.
segemnts labour, survey, assembly/dismantle. Design Site preparation, paints/glues, Manchester Gates regime, spare/wear parts, workshop & turnaround time of skip ground treatment, drilling Structural assessments.
consummables. 'Loca' of TBM to ease assemby, tpt access, covers to segments. tools. Tea cabin/toilet. Sretcher. emptying. Wheeled vehicles, pipe from tunnel.
labour and skill level. etc. Communication. Self breathers. & piston pump, conveyor.
Drilling and grouting equipment. Vertical conveyor.

TBM Review meetings and Access / Egress Safe Max loads & cranes SHAFT Lighting, comms, dust, noise Installation, assembly & recovery Overall rate of advance and Grout delivery system, from Emergency plan & call out.
reporting on routine & walkways/routes sequence + T&C. Lifting equipment & extraction/disposal. surface/torpedo, skip, grout Immediate response to
high risk areas. testing pan. collapse, holes.
Progress rates Emergency RV Sacrificial tail skins? Location of supports Inspections Advance procedure/method, stock of Compatibility of advance/muck Trigger levels & response.
material rate.
FIT OUT Power Supply BREAK IN/OUT Access ladders/hoist Survey stations Face pressure control
MEP Emergency Generators Soft eyes & hacking, collars, Lifting & line of sight Drainage TBM ADVANCE SEGMENT HANDLING SEGMENT REPAIRS SUB-SURFACE
receiving block /ERECTION MOVEMENT
Facilities, Logistics, Cranes / Gantries. Grouted areas Lighting Fire Main Face pressure control. PLC limits. Correct ring sequence for build Types- cracks, spalling, Reaction of lining, lateral
sequencing, perm /temp Hardstandings, ground Operator/engineer/surface leaking, wet. Records of movement, deep
configuratiion treatment required. supervision. damage,location,cause(for foundations.
mitigation)
Lifting Operations Thrust frame, scaffolds Control of access, comms Fixing Brackets Face pressure maintenance Shaft lifting operations Materials & tools. MANAGEMENT
Offices & car parks Temp support Flood protection Trackbed concreting Soil conditioning (vol, type, tests) Stacking on flatbeds Personnel, equipment. Organisation & comms
SEGMENT Washing Bays & Dust Temporary rings PIT BOTTOM Repairs to segments, leaks Steering (ram usage), alignment Unloading/stacking in TBM. Scafflold, access, lighting, Daily review. Consolidated
PRODUCTION Control etc. correction. Rate of advance Check lifting devices/lugs tc. ventialtion. drawings. Analysis of
TBM records &
settlement.
Factory, transport, Segment Integrity of structure Hot works Recovery of temporary Screw conveyor rate and gate Ring Build:plane check, lips, Testing, pull out/strength, Progress - cycle times,
storage, logistics, records preparation/handling eqpmnt. opening. Monitoring weight/volume & steps, gasket damage, position surface finish. Laekage down time, waiting time,
, birth certificate to possible overexcavation. check, packing, survey. mainatanace, o/a
installation, efficiency.
Materials, gaskets, Neighbours SURVEY Segment/muck handling Task ventilation Comms with surface, daily/shift TBM build area,platforms, Repair procedures & samples. Safety Inspections, tool
repair, instructions. Ordering equipment. access, lighting, ventilation, box talks. Risks with time
visibility, signals. Personnel. & location of TBM
Follow-on works Baseline control & advance. Train/personnel interaction. Lighting at points & SOP's for likely scenarios, Control & position of erector, Site supervision. Site
requirements frequently visited areas. grout/muck/face pressure rams, air tools. Control. Sub-con comms.
Muck handling Method of establishing Fire point, comms, first aid, Control of thrust & torque. Pitch, roll Segment design compatible with Alignment management.
arrangements line/level. lights, signals & yaw. Ring build requirements. erector,lifting equipment. Emergency plan, method
Advancing/relocating & fixing Laser/gyroscope guidance system. statements, Risk
survey points, TBM guidance register, Procedures,
systems. Quality paln, I&TPs
TBM/TUNNEL CHECKLIST

Management

Alignment Design Risk Assessments

Lining Design Emergency Plan & Contingency Measures

Cross Passage Design Organisational Structure

TBM Design Programme for Reviews

Site Investigation Reports Construction Programme

Settlement Analysis QA Review Plan

Building/Utility Protection Muck Disposal Plan.

Instrumentation & Monitoring Plan Alignment Review

NOTICE TO PROCEED As-built drawings

Shaft/surface design Completion Report

Supervision Site Utilisation Plan Method Statement & Risks

Survey & Setting Out Safety Plan & Inspections

TBM Assembly & Launch Sequence Review of Data & Corrective Actions, Daily
Instructions.
Break-in & Break-out Methods Permits to Work

T&C of back-up facility, cranes etc. Material Data Sheets

Approved Materials & Repair Methods QC Verification Plan

Records of TBM Operation, breakdowns etc. Alignment Management

Muck Disposal Management TBM Removal & Turnaround

Ventilation Stop/Restart. TBM Stop/Restart

Train configuration & sequencing Movement Control of Personnel.

Process Method Statements & Site Records Risk Assessment & Mitigation

TBM Operation -face pressure, steering, speed, SOP's- TBM Operation (pressure loss, loss of ground,
thrust, torque, delays, excavation times, inflow of water, adverse surface settlement,
weight/volume excavated, additives added. overexcavation, stop/start)

TBM Advance protocol/safety wrt operators. Monitoring frequency & reporting

Segment Erection-lifting, accessories, location, safety Instrument Installation Method

aspects, build record.

Segment Repairs/leaks Tailbrush Replacement

Alignment Control -steering, reporting, corrective Hot works procedures

action.

Grouting - mix, pressure/volume, sequence, records, Site/Tunnel Safety -ventilation, lighting, air quality &
eqpmnt. temperature, dust, noise, communication, fire, power

Muck Disposal records Lifting Operation Procedures

Locomotive Operational Procedures & derailment & Emergency Plan for tunnel evacuation.
runaways, Signals

Lifting and Pit/Shaft Bottom Procedures Grouting works/building protection works method
statements.

Cross Passage Construction. Survey Control & station advance

Trackbed cleaning, concreting Train Configuration/material delivery & supply. Call

forward procedure.

Walkway Construction Tool Box Talks/meetings

Bracket Installation

Tunnel Equipment Removal