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Geometrical Design of Launch Shaft for Mechanized shield Tunneling

Conference Paper · May 2012

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Geometrical Design of Launch Shaft for Mechanized shield
Tunneling

HADI GHODRAT1, MOHAMAD KHOSROTASH2, MOJTABA TORABI3, MEHRAN

KHOSROTASH4
1
Shahid Hasheminejad Gas Processing Co., Iran
2
SABIR Co., Iran
3
SABIR Co., Iran
4
SABIR Co., Iran

ABSTRACT

Several criteria are effective on suitable site selection of launch shaft for mechanized shield
tunneling. One of important mentioned criteria is geometrical design and final dimensions of
shaft. This criterion is especially considerable in urban tunnels such as utility tunnels or
subway which TBM launch (or external) shaft layout is usually affected by space limitation,
interference utilities and geotechnical hazards. It is obvious that technical and economical
risks of mechanized shield tunneling projects could be decreased considering all required
spaces and dimension optimization of them. In this paper, the authors based on varied
experiences of mechanized shield tunneling inside and outside of Iran present affecting items
on geometrical design of mechanized shield tunneling launch shafts and optimization
suggestions of various spaces.

1 INTRODUCTION

Tunnels are playing an important role in the development of urban infrastructures. Several
construction methods for tunneling have been developed to cope with various geological
conditions which can be categorized in two types such as drill and blast method and by the
use of Tunnel Boring Machine (TBM) which is named as mechanized tunneling. Recently
mechanized tunneling in urban area has many progresses in several parts such as design,
equipment and construction. The experiences of different urban projects shows that
mentioned items have close relationship with themselves during the whole project. It
decreases the defections of mechanized tunneling method and consequently construction
risks and challenges decrease. Design progresses of mechanized tunneling in urban area
and risk reduction procedures are indebted to several published engineering experiences
and researches such as Carrieri et al. (2004), Chiriotti et al. (2001 to 2004), Grasso et al.
(2007) and Guglielmetti et al. (2008) ….
The selection of an optimal urban tunnel alignment should consider the location of the
tunnel starting and arrival points, the location for the TBM-launching and receiving shafts, as
well as the huge space required for organization of logistic worksites to support the
industrialized construction process. In fact, it is always necessary to consider the location of
the TBM launching shafts in well defined areas, outside the historic centre and connected to
a good road system.
 The size of the areas necessary for the logistic sites can vary considerably according to
several items. In this paper, the authors based on varied experiences of mechanized shield
tunneling inside and outside of Iran present affecting items on geometrical design of
mechanized shield tunneling launch shafts and generally a collection of optimization
suggestions for various spaces will be presented.

2 SUBJECT NECESSITIES

In comparison with tunneling in open-space rural areas, tunneling in urban areas has some
major and peculiar characteristics and constraints as listed below (Guglielmetti et al. 2008):
• The layout is strictly related to the final use and to the functional aspects of the tunnel.
Hence, in spite of the apparent “topographic freedom” of the 3-dimensional planning, many
constraints intervene to limit the alignment and launch shaft location, resulting in frequent
and often unavoidable, potential interferences with buildings at the surface, underground
utilities, and other pre-existing underground structures.
• The accessibility for doing the necessary site investigations can be limited due to a lack of
permission or to the occupation of the surface.
• The sub-surface at shallow depth often consists of loose soils, alluvial deposits, or
manmade fills. The poor quality of the ground is one of the key factors for the launch shaft
design and construction control.
• The immediate underground level of the sub-surface is reserved to the installation of
underground utilities that have to be identified and assessed, in terms of the risk of potential
damage caused by tunneling-induced settlements, and subsequently diverted and relocated
permanently, if needed.
• In many parts of the world, the cities have an important historical background. Hence, in the
immediate underground level of the sub-surface, important archaeological features could be
hidden; these have to be recognized and dealt with, especially when planning the tunnel
accesses or the service shafts.
• The high level of interaction with the life above the surface has to be analyzed and solved
carefully with solutions that can be accepted by the public without causing major
disturbances. This implies an appropriate plan for the temporary diversion of the traffic, an
accurate planning of worksite areas, a particular attention to control of dust and noise
emissions, and a special care for safety issues.
• Urban tunneling is generally related to the implementation of strategic infrastructure
projects, which have a high political relevance. The politicians and the financiers of the
project, together with the public, will all demand for a certainty of the project budget in terms
of cost and duration.
Generally, the main sources of risk associated with urban mechanized tunneling
projects are related to geology and hydrogeology, design, and construction (Chiriotti et al.,
2003). It is true that nowadays there are modern construction tools to deal with hazards and
manage the consequent impacts, but it is definitely more convenient and economical if most
of the high level risks can be totally avoided through the correct choice of the alignment and
launch shaft location. Consequently, the authors seriously emphasize on the importance of
correct decision about the location, underground structure type and geometry of start point
which is technically named “launch shaft” in mechanized tunneling.
3 LAUNCH SHAFT GEOMETRY; INFLUENCING CRITRIA

3.1 Tunnel Boring Machine (TBM) dimension

Tunnel boring machine (TBM) dimensions are the basic and important items effecting on
launch shaft dimensions. Some items such as shield and connecting beam length and
number and length of the machine decks effect on launch shaft length and cutter head
diameter is the most effective item on determination of launch shaft width.

Back Up TBM

Figure 1 Schematic TBM

Figure 2 shield (or cutter head) diameter which is influencing on launch shaft width

3.2 TBM start-up method

The shield or TBM is usually moved forward using jacks pushing on the erected segmental
concrete lining. For the first TBM movement at the start of excavation, TBM usually requires
a steel structure which is named pushing frame. Dimension of this structure can be
concluded from structural design methods and it is directly related to trust force and TBM
torque magnitude. Pushing frame dimension influences on launch shaft width. Incorrect
determination of launch shaft width considering retaining structure dimension in SHIRAZ
subway, forced the design team to change one of pushing frame backward supports during
the installation (fig 3). Moreover, some mixed methods are probably applied. Khosrotash et
al. (2009) states an inventive method for TBM start up. In mentioned method, firstly, tunnel
face is excavated by NATM method. Then TBM enters the eye tunnel and pass it by segment
arranging and after that it starts excavation. As an optimization suggestion, the effect of TBM
start up method on launch shaft width will be canceled in this method (fig 4).
Figure 3 Compulsory change in backward support of pushing frame in SHIRAZ 2nd TBM

Figure 4 Inventive method which is applied by Khosrotash et al. (2009) in SHIRAZ subway

3.3 Montage and service holes

In order to install the TBM cutter head, applying a predicted hole can improve the speed and
qualification of montage stage. This predicted hole is named as "montage-hole" by authors.
Minimum dimension of this hole should be equal to cutter head diameter in length, 1 meter in
width and at least 0.5 meter in depth. It is better that the location of the montage-hole is
considered near the start up wall (Minimum distance about 1 meter is appropriate.).
Mentioned hole would be applied to ease of montage of cutter head. As an optimization
suggestion, the designer can decrease launch shaft dimension using montage-hole and
applying the depth except launch shaft plane dimensions such as length or width. The other
hole which should be considered in launch shaft is service-hole which should be located in
articulation joint place. The tail-skin, behind and connected to the shield, is a space used for
assembling the lining rings. There is a complex seal system between the tail-skin and the
previously installed lining. Moreover, the junction between the shield and tail-skin is
engineered to allow relative movements between the two parts. This is the articulation joint
by which the machine can be steered around curves. The joint has an adjustable seal,
excluding water when working in saturated ground. As an innovation which is applied by
authors in mechanized tunneling projects, Service-hole should be considered at the location
of articulation joint in order to more accessibility to this region and ease of complicated
assembling activities there. The length of service hole is suggested at least equals to cutter-
head diameter and its width and depth about 0.7 meters would be appropriate (figs 5 & 6).
Figure 5 Schematic of the Montage & Service holes

Figure 6 the Montage and Service hole which is used in SHIRAZ TBM montage

3.4 Launch shaft stabilization method

In order to stabilize the launch shaft of mechanized shield tunneling several methods may be
applied such as:
• Using self-stabilized trench or berm
• Using reinforcement systems such as:
- Nailing and anchorage
- Reinforced soil (geo grid and geo textile)
- Micro pile
• Using structural elements such as:
- Under pressured vertical and horizontal elements (pile and strut)
- Steel truss
- Sheet pile
- Soldier pile
- Diaphragm (slurry) wall
Although abundant progresses are occurred in construction methods and tools, but the
most important criteria which must be considered to select launch shaft stabilization method
are available space, construction schedule and time limitations, geotechnical condition and
difficulties (soil type, density, water table and …), and also economical considerations.
Considering mentioned items, experienced designer could be able to suggest the most
optimize method for stabilizing the launch shaft. Then the "actual shaft geometry" could be
estimated here which is usually larger than "net" shaft dimension.
3.5 Site mobilization considerations

One of important items which should be taken into account in launch shaft geometry is site
mobilization considerations. The mentioned item contains as below:
 Utilities: mechanized tunneling by TBM requires some utilities such as waste water
treatment system, water and waste water sumps. In order to respect environmental rolls,
waste water produced during tunneling, especially under water table, must be treated using
an appropriate system which is usually located in launch shaft in urban mechanized
tunneling projects. Required space for mentioned system will affect on launch shaft
dimension. Usually some sumps should be considered for collecting tunneling waste water
and transmitting it to the treatment system. Number and dimension of them are related to
estimated waste water quantity and number, type and dimensions of main and reserve
pumps. Moreover, because usually mechanized tunneling launch shafts are uncovered
(without roof), hence there is some water due to raining and snowing. Sometimes the water
quantity is too much, especially in launch ramps which is affected by raining concentration
time and ramp steep. So, similar to waste water, a collecting system contains some sumps
and pumping system should be considered which must be taken into account in launch shaft
dimension.
 Muck removal system and temporary muck depot: tunneling excavation deposits named
“muck” must be removed from tunnel space simultaneously. Some technical and economical
criteria are affecting on the type of muck removal system, steel muck car or belt conveyer
method (Noda et al., 2005). For small diameter tunnels where working space is quite limited,
a screw conveyor and belt conveyor are required (ITA-WG14, 2000). The designer should
determine the dimension of the system which is necessarily located in launch shaft area. The
system dimension is effective in determining launch shaft dimension. Relating to the method
proposed by designer, it may require saving a special space for temporary muck depot which
must be considered in launch shaft dimension (fig 7).

Figure 7 muck removal systems and temporary muck depot area

 Rolling stock: mechanized tunneling is not possible except supporting TBM by rolling
stock system. Based on several considerations, number and type of the system may be
different. Generally, both on rail and on tire systems are popular in urban projects and
selecting each other relates several criteria especially it relates to maximum alignment
gradient. The number of the sets relates to tunnel excavation schedule. Moreover, the deck
number and the length of each other relates to service purposes of the system. Usually
rolling stock systems contain grout car, flat car, personnel car and segment car. According to
expressed criteria, the designer must determine the type, number and final dimension of the
system. The designer may propose on rail system considering mentioned criteria, if so it is
necessary to consider appropriate space for rolling stock maneuver and the system reserve
parts. Therefore, rolling stock system characteristics influence on launch shaft length.
Figure 8 rolling stock

 Ventilation system: similar to the other tunneling methods, mechanized tunneling strongly
needs a ventilation system to overcome risks such as dangerous underground gasses and
tunnel air condition becomes health. Although all parts of this system in the tunnel are air
ducts, but other parts of the system must usually located in launch shaft. So, the ventilation
system dimension should be considered in lunch shaft dimension.

Figure 9 ventilation system

 Grouting equipments: settlement control at the ground level is usually done using grouting
method which fills empty space between excavated surface and outer segment surface in
urban tunnels. If a grouting equipments package supplies tunneling far from excavation face,
grout car can be emitted from rolling stock package. On the other hand, grouting equipments
containing cement and sand silos, water, retarder and accelerator sumps, mixing and
pumping system should be located in shaft space which must be taken into account in
required launch shaft space.

3.6 Temporary segment depot

According to predicted tunneling progress rate (meters per day) and designed segment (or
ring) width, the designer can estimate the number of required segment per a work day (24
hours). Usually because the segment plant in urban mechanized tunneling projects is far
from the segment installation location, deposition of about 48-hours required segment for
TBM in launch shaft appears reasonable.

3.7 Future application of shaft

If the launch shaft will be applied as exit point of subway at the ground level, it would be
more reasonable to construct a ramp in replace to a launch shaft.
 4 CONCLUSIONS

This paper focuses on effective criteria on suitable site selection of launch shaft for
mechanized shield tunneling and geometrical design and final dimensions of shaft as one of
important mentioned criteria is studied. Necessities of the subject are expressed extensively
and direct relationship between geometrical design accuracy and risk reduction of
mechanized tunneling is clearly stated. This paper studies which are based on the authors
experiences in mechanized tunneling, shows that generally the criteria which are influencing
on launch shaft geometry are tunnel Boring Machine (TBM) dimension, TBM start-up
method, montage and service holes, launch shaft stabilization method, site mobilization
considerations (including utilities, muck removal system and temporary muck depot,
ventilation system, rolling stock, grouting equipments), temporary segment depot and future
application of shaft. Actually there is a belief that probably concealed items may be added to
the mentioned list.
Consequently, determination of final dimensions for launch shaft in mechanized shield
tunneling follows from a trial and error process and the most important item which can help
the designer in finding the most accurate answer is recognition of influencing criteria.

REFERENCES

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