TUNNEL ENGINEERING COURSE

(MODULE 4) AT MINING UNIVERSITY

LEOBEN, AUSTRIA
06 – 24 APR 2015
 Feedback Report
FEEDBACK REPORT FOR TUNNEL ENGINEERING COURSE (MODULE 4)
AT MINING UNIVERSITY LEOBEN, AUSTRIA

06 – 24 APR 2015

Introduction

1. BRO was raised in 1960 with the aim of improving connectivity to the NE and
Northern areas. During war, BRO resources carry out engineering tasks (roads/bridges etc)
related to the progress of army operations. BRO primarily works on the GS roads. In early
2000, when MoRT&H started expanding in North and NE regions, there were no worthwhile
construction agencies available for works there. Since most of the existing roads in these
areas had been constructed and maintained by BRO, these works were entrusted to BRO.
Presently, BRO has 70% of its workload as GS Works and 30% as Agency Works, including
MORT&H & MEA etc.

2. There has been a phenomenal increase in quantum of works entrusted to BRO.

Impetus to construct roads to China border was given in 2006 when there was a sudden
rush to identify requirement of roads leading to border areas. More than 400 roads were
identified and tasked to BRO to be completed in a time-bound manner. Similarly, in the past,
MORT&H has been gradually notifying roads constructed by BRO as NH, and they have
been entrusting these to BRO because of total void of any infra-structure developing agency
in these far flung areas. SARDP programme, Arunachal Pradesh package and Prime
Minister Rehabilitation programme for J&K were being conceived from 2004 onwards.
Majority of these roads were Class-9 Single Lane roads constructed by BRO. Hence, BRO
was their only choice for improving these roads to NHDL specifications. Also, NEC was the
major road funding agency in the North East and a large number of NEC roads were
entrusted to BRO for construction. Besides this, MEA and MHA also chose BRO for their
road works.

Tunnels in BRO

3. Construction of tunnels is not literally new for BRO. A RCC Cut-and-Cover tunnel
(120 mtr) and allied works for Sonapur land slide located at Km 141.74 on Road Shillong-
Jowai-Badarpur-Churaibari (NH-44) have earlier been completed and dedicated to the
Nation. The under-mentioned tunnels are in various stages of construction or planning with
BRO :-

S No Name of Tunnel State Length (Km) Status

Constr under Progress
4.8 km progress of heading achieved
(a) Rohtang HP 8.8
up to 18 Jan 2015.
Sanctioned/ Contract Action in Progress
(b) Theng Sikkim 0.58 Works likely to commence by Jun/Jul
Consultancy for Feasibility Study Approved by GOI
(c) Razdhan Pass J&K 18 Feasibility study in progress
(d) Rudraprayag Uttarakhand - do -
(e) Sadhna J&K 6.12 Feasibility study under tender action
(f) Baralachala HP 11 - do -
(g) Shinkunla HP 4 - do -
(h) Lachung La J&K 14.8 - do -
(j) Tanglang La J&K 7.3 - do -
(k) Mile 13 (Km 18.35) Sikkim 1.25 - do -

4. A need is now felt to hone our in-house skills to monitor planning, construction and
management issues associated with tunnels in BRO. In tune with this, a team of four BRO
officers was sent to Mining University Leoben (Austria) to attend a 3-weeks course in
tunnel engineering from 06 to 24 Apr 2015.

Nomination of Officers

5. The following officers were nominated for the above course :-

(a) Col Sunil Kumar, Director TP (Res) / HQ DGBR

(b) Lt Col Deepak Patil, E8 Section / HQ DGBR

(c) Shri MC Navanath, EE(Civ), 63 RCC / Project Dantak

(d) Shri Dinesan Karayi, AEE (Civ), 1445 BCC / Project Himank

Move and Administration

6. Upon receipt of confirmation of seats on the course, necessary papers were moved
to obtain MEA and political clearance. It took considerable time for the above clearances to
get through.

7. Once the clearances were received, the nominated officers were mustered at HQ
DGBR and steps initiated for issue of Official Passports by MEA (CPV division), purchase of
required air tickets by the officers, booking of accommodation near University premises and
issuance of visa by the Austrian Embassy in New Delhi. The whole process was completed
in about seven working days’ time.

8. Efforts by the officers from HQ DGBR to draw an advance for the course could not
materialize since no VOA (vote-on-account) allotment was available with the PCDA (BR).
These officers had to arrange for their onward as-well-as return air tickets and daily
expenses in Austria on their own. Fortunately, a last-minute confirmation was received from
the Indian Embassy in Vienna that the course fees and accommodation charges for all four
officers had been tied up and paid by them.

9. The following courtesy was extended to the team by the Indian Embassy at Vienna :-

(a) The course fees of Euro 3,000/- per student was paid by them.

(b) The accommodation at Leoben for all students was arranged and paid for by
them.

(c) The reception of the students and provision of one-way taxi from Vienna
airport to Mining University Leoben was arranged and paid for by them.

(d) Audience by the Ambassador Shri Rajiva Misra to the team was granted on
24 Apr 2015.

10. The University and the accommodation (Hotel Kindler) were within walking distance
and hence there was no need of arranging any transport for this purpose.

About Mining University Leoben (Austria)

11. The climate. The climate in Leoben is continental, i.e. cold winters (lows are –10° to
–15°C) and hot summers (around 30°C). In the winter, some snow can be expected.
However, the houses are well insulated and have central heating, so the temperature
indoors is always comfortable.

12. Location. Mining University Leoben is located at a distance of 164 kilometres

from Vienna International airport and can be reached via taxi, train and community bus or a
combination of all these in about 3 to 4 hours. The location is as shown below on the map :-
13. Various courses available at Mining University Leoben, Austria are as given at Appx
‘A’.

Tunnel Engineering Course

14. Aim. The aim of Tunnel Engineering Course is to satisfy the continuously
increasing worldwide demand for qualified tunnel engineers by increasing the skills of the
participants in the fields of geotechnical engineering and tunnelling, with an emphasis on
NATM.

15. This course, Module 4 of Tunnel Engineering, was jointly organized by the Graz
University of Technology and the Mining University of Leoben, Austria.

16. The course addresses civil engineers, geotechnical engineers and engineering
geologists who do have a distinctive technical education and aim at a specialization in
conventional tunnelling. Future fields of work may be planning, design and consulting of
underground projects for engineering offices, or construction management for departments
and contractors.
17. After successfully participating in the Certificate Course (i.e. after all four modules),
students have the option to continue with the course for another two semesters and receive
the title ‘Master of Engineering’.

18. Course Content. Course Content of Tunnel Engineering Course is as given out
at Appendix ‘B’.

Module 4 of Tunnel Engineering Course in a nutshell

19. Purpose of monitoring. As excavation of a tunnel progresses, the created opening

into the ground begins to deform due to overburden and a host of geological factors
including faults in the vicinity of the created opening. Monitoring of these deformations at
regular intervals of distance and time is important and must be done religiously. Monitoring
would involve the following :-

(a) Observe system behaviour and check if it is within the acceptable range.

(b) Use data to verify assumptions made during design on ground behavior.

(c) Calibrate models.

(d) Use results for fine tuning of excavation and support.

(e) Use data for prediction of ground structure and quality ahead of the face.

(f) Proof that prescribed limits are kept (for example surface settlements).

(g) Legal aspects.

20. Earlier methods of monitoring. In Austria, the earlier methods available for
measuring deformations within a tunnel were not very scientific. Only the relative
displacements between six points were generally observed. This could not establish if the
tunnel as a whole had any lateral shift or angular displacements. Following two methods
were used :-

(a) Measurement of relative displacements

(b) Relative displacements using extensometer. This method was only a

slight improvement over the previous method. The relative displacements were
measured with respect to rock mass in the ground which were “assumed” to be
stationary.
21. The Present Method of monitoring displacements. Absolute measurements
are being made using high-precision total stations. Various types of mechanical / electronic
strain gauges are also used. This offers the following advantages, however, the accuracy
depends on measuring distance, air quality (dust, temperature) and stability of reference
points :-

(a) Measurement with freely positioned total station.

(b) Minimal obstruction of traffic.

(c) Knowledge of movement of each point in space.

22. Typical development of displacements is as shown below. The central vertical dark
line depicts the face of the tunnel at any point of time. The monitoring gauges have been
placed at intervals of 5 metres behind the tunnel face (right half of the graph relates to it).
The displacements ahead of the tunnel face cannot generally be measured and are only
predicted based on displacements measured behind the tunnel face. Following can be read
from the plotted graph :-

(a) Displacements predicted upto 5 metres ahead of the tunnel face are much
less compared to those behind the tunnel face. However, these displacements are
most important for purpose of planning excavation ahead and kind of support
measures required.

(b) The maximum displacement occurs within hours of the excavation, and
continues till the excavation has progressed ahead generally by 25-30 metres in
normal cases.

(c) Displacements are never ending, albeit at much smaller rates which are
negligible with time.

(d) The periodicity of recording measurements at regular intervals of time can be

reduced y when the tunnel has sufficiently advanced from the point in question.

(e) Any deviation from the predicted displacement at any point (and adjoining
points) should be carefully studied, as the same may be due to geological faults /
fractured rock mass in the vicinity of the point. This may necessitate a change in the
followed rate of excavation, change in design and a change in the support measures.
23. Data Interpretation. Data interpretation is as important as accurately recording the
target data. Various warning levels may be set where the actual displacements are at gross
variance from the predicted displacements to effect required changes in design and support
measures.

Lessons from Module 4

24. The present method of contracts being followed i.e. Lump-sum, EPC, or FIDIC model
shall not work in case of tunnels owing to the following reasons :-

(a) Not adaptive to geological surprises. Geology dictates the total time
and cost of excavation. Change in geology means a change in total time and cost of
completion.

(b) Fixed time frame and total cost. It does not cater to requirement of flexibility
in time and cost due to change in geology.

(c) Maximum risk on the Contractor.

 (d) Monitoring of geotechnical data. Constant monitoring during construction
is very important, for incorporating changes in design, if necessitated, and also for
safety management. It also helps us in forecast of geology ahead. However, this is
generally missing.

(e) Disputes Adjudication Board (DAB) consists generally of a single member.

25. Observed in most of the running contracts in India.

(a) We do not employ an experienced tunnel expert.
(b) Inadequate inventory in the bill of quantities, e.g. rock bolts and pipe-roofing
generally excluded.
(c) Time-dependent costs are generally on the higher side.
(d) Functioning of Joint Venture not elaborated in the Contract.
(e) Geotechnical monitoring not being done by an independent body.
(f) Billing by an Independent Engineer. Client has limited say.
(g) Delayed decision by Client in deviation orders, variation orders / star rates.
(h) Designer not responsive to geological surprises.
(j) On-line monitoring of tunnel displacements should always be incorporated in
the Project.

Recommendations

26. Raising of a Tunnel Construction Company (TCC) to take on a pilot project.

As per assessment by a BOO, we may raise a TCC. Initial technical support may be
sought through contract / private firm which will impart on-the-job training to departmental
manpower. Once in-house expertise develops, this technical support (through contract) shall
be withdrawn. However, instrumentation and geotechnical monitoring including design
support and response to geological surprises may continue to be obtained from a consultant.
27. Adopt Contractual Process developed by the Austrians.
(a) Definition of tunneling classes. Not from the point of pure geology, but
from the point of necessary support materials and round length.
(b) Direct costs of equipment & machinery involved in drilling works, and
consumables including support measures.
(c) Indirect costs – time depending costs (site office, staff and machinery not
already included in direct costs). They shall be shown as separate items in the BoQ.
(d) Agreed working time schedule, divided in :-
(i) Installation phase.
(ii) Tunnel driving.
(iii) Tunnel driving and simultaneous final inner lining.
(iv) Final Inner lining after tunnel driving.
(v) Completion works after final inner lining.
(vi) Compensation for more than one tunnel driving simultaneously.
(e) Flexible construction time. All direct costs depend mostly on qty whereas
non direct costs are time related.
(f) Tunneling time shall be defined as under :-
 (i) Actual tunneling time. Actual time of the tunnel driving,
including shut-down and interruption times.
(ii) Predicted tunneling time. Data from the tender (tunneling classes,
complications, shut-down times). This shall mean the target time.
(iii) Contractual (payable) tunneling time. Time of the actual
tunneling classes and accepted shut downs, interruptions.
(g) Financial compensation to contractors.
(h) It is generally a system with which you can “ensure changes within the
contractual conditions”.
(j) Appointment of a tunneling referee, comprising of
(i) Geotechnical advisor.
(ii) Independent expert, and
(iii) Mediator.
28. Following is the recommended frame-work of contract :-

29. Following frame-work for risk-sharing may be followed :-

 Photo No. 01: Mining University Leoben : Tunneling Faculty

Photo No.02 : BRO Memento to Ambassador Shri Rajiva Misra

Photo No. 03 : Attendance Certificate by Prof Rober Galler

Photo No. 04 : Lattice Girders for In-situ casting of lining

Photo No. 05 : Drilling Head of Self Drilling Bolts

Photo No. 6 : Self-drilling bolts

Photo No. 7 : Face plates for Rock Bolts

Photo No. 8 : Wire Mesh for Shotcreting

Photo No. 9 : Collapsible Ventilation Pipes

Photo No. 10 : Rock Core Samples

Photo No. 11 : Live Testing on Pre-cast Support Lining

Photo No.12 : Slope Stabilization for Tunnel Entrance

Photo No.13 : Slope Stabilization for Tunnel Entrance

Photo No. 14 : Self Drilling Bolts being placed

Photo No. 15 : Tunnel Face Stabilization using rock bolts

Photo No. 16 : A Typical Face of a Tunnel

 Photo No. 17: Drilling of Holes by a Boomer

Photo No. 18 : Electronic Survey for Qty Calculation

Photo No. 19 : Shotcreting in progress

Photo No. 20 : Additional Rock Bolting

Photo No. 21 : Services for the Tunnel

Photo No. 22 : Services for the Tunnel

 Appx ‘A’

VARIOUS COURSES RUN AT MINING UNIVERSITY LEOBEN, AUSTRIA

S No Studies Code Credits Semester Degree

1 Bachelor programme
(a) Applied Geosciences (UG2002/15U) 206 210 7 BSc
(b) Industrial Energy Technology (UG2002/15U) 276 210 7 BSc
Industrial Environmental Protection and Process 212 210 7 BSc
(c)
Technology (UG2002/15U)
(d) Industrial Logistics (UG2002/15U) 214 210 7 BSc
(e) Materials Science (UG2002/14U) 210 210 7 BSc
(f) Mechanical Engineering (UG2002/14U) 207 210 7 BSc
(g) Metallurgy (UG2002/15U) 224 210 7 BSc
(h) Mineral Resources Engineering (UG2002/15U) 208 210 7 BSc
(j) Petroleum Engineering (UG2002/15U) 241 210 7 BSc
(k) Polymer Engineering and Science (UG2002/15U) 220 210 7 BSc
(l) Recycling (UG2002/15U) 246 210 7 BSc
2. Master programme
(a) Applied Geosciences (UG2002/14U) 406 90 3 Diploma
(b) Industrial Energy Technology (UG2002/14U) 476 120 4 Diploma
Industrial Environmental Protection and Process 412 90 3 Diploma
(c)
Technology (UG2002/14U)
(d) Industrial Logistics (UG2002/14U) 414 90 3 Diploma
Industrial Management and Business Administration 442 90 3 Diploma
(e)
(UG2002/14U)
International Master of Science in Advanced Mineral 478 120 4 MSc
(f)
Resources Development (UG2002/14U)
International Study Program Petroleum Engineering 441 90 3 Diploma
(g)
(UG2002/14U)
(h) Materials Science (UG2002/14U) 410 120 4 Diploma
(j) Mechanical Engineering (UG2002/14U) 407 120 4 Diploma
(k) Metallurgy (UG2002/14U) 424 90 3 Diploma
(l) Mining and Tunnelling (UG2002/14U) 408 90 3 Diploma
(m) Polymer Engineering and Science (UG2002/14U) 420 90 3 Diploma
(n) Raw Materials Engineering (UG2002/14U) 409 90 3 Diploma
(o) Recycling (UG2002/14U) 446 120 4 Diploma
3. Doctoral programme
Doctoral programme (UG2002/11U) 787 180 6 Doctorate
4. University course
(a) Advanced Drilling Engineering (UG2002/13U) 152 114 4 MEng
(b) Blasting Engineering (UG2002/12U) 136 32 2 -
(c) CorrosionExpert (UG2002/14U) 208 15 1 -
(d) International Mining Engineer (UG2002/12U) 151 62 4 -
(e) MBA Generic Management (UG2002/14U) 540 90 4 MBA
 NATM Engineering (New Austrian Tunnelling Method 109 61 4 -
(f)
Engineering) (UG2002/08U)
(g) NATM Master of Engineering (UG2002/11U) 193 90 6 MEng
(h) Product Development (UG2002/13U) 178 60 3 -
Quality Assurance in the Chemical Laboratory 145 15 1 -
(j)
(UG2002/01U)
(k) Quality Management (UG2002/07U) 971 61.5 3 -
(l) Raw Material Processing (UG2002/12U) 290 60 2 -
(m) Recycling (UG2002/11U) 192 60 3 -
(n) Resource Management and Recycling (UG2002/12U) 197 90 4 MEng
(o) Sustainability Management (UG2002/07U) 552 68 3 -

Appx ‘B’

Complete Course Content : Tunnel Engineering

Investigation and Ground Characterization

1. Introduction
(a) Historical review of the development of tunnelling, fundamentals of NATM, its
advantages and disadvantages in comparison to other methods.
(b) Procedure of design and construction under consideration of the basics of the
observational method.
2 Investigation
(a) Overview of requirements, methods and analysis of engineering-geological
investigation methods.
(b) Planning of exploration programs depending on the project stage, the
requirements and the geological conditions.
Overview of appropriate investigation methods :-
(c) Engineering-geological field mapping tasks, methods, models, thematic
maps, field methods to identify parameters.
(d) Reporting: Structure, requirements, contents, international standards,
selected examples.
3. Classification and Characterization
(a) Classification and Characterization of Rock and Rock Mass.
(b) Determination of Ground Types.
(c) Determination of mechanical and hydraulic rock parameters, objectives and
methods.
(d) International standards and guidelines.
4. Laboratory Testing
Rock mechanical laboratory techniques and test methods, analysis, determination of
parameters and compilation of a lab report.
Geotechnical Design and Tunnel Layout
1. Geotechnical Design
 (a) Introduction to structured design approach.
(b) Identification of influencing factors.
(c) Analysis of ground behaviour, using closed form solutions and numerical
simulations.
(d) Support methods, effects and characteristics of supports.
(e) Assignment of excavation and support methods to characteristic geotechnical
situations
(e) Analysis of system behaviour; estimation of stresses and deformation,
structural design of shotcrete linings.
(f) Special measures in soft soils, for tunnels with high overburden, and tunnels
below the groundwater table.

2. Numerical Analysis
(a) Fundamentals of simulations
(b) Available material models in the field of geo-numerics.
(c) Fundamentals in FE- programmes: FLAC, UDEC, Plaxis, ABAQUS.
(d) Pre-processing, Post processing.
(e) Compilation of inputs.
(f) Interpretation of results.
3. Tunnel Layout
(a) Basic approach in the development of tunnel profiles
(b) Clearance profile
(c) Ducts, cables, and drainage.
(d) Ventilation systems.
(e) Safety installations, fire protection.
(f) Waterproofing and drainage systems.
(g) Inner lining design; requirements, regulations.
(h) Sequential excavation: typical excavation and support sequences, criteria for
application, structural details.
(j) Construction sequences for large underground openings, bifurcations,
underground stations, etc.
(k) Excavation methods in soil and rock; typical fields of application, criteria and
limitations.
(l) Design of tunnel profiles: use of ACAD.
4. Risk Analysis and Management
(a) Risk analysis methods.
(b) Definition of requirements and boundary conditions.
(c) Identification and quantification of hazards.
(d) Evaluation of probability of events.
(e) Evaluation of risks.
(f) Selection of mitigation measures.
(g) Corridor assessment, route selection.
Site Organization, Construction Contract and Construction Management
1. Site Organization and Construction Management
(a) Work preparation in tunnelling.
(b) Equipment and staff disposition.
(c) Estimation of performance.
(d) Cost estimation.
(e) Basics of tunnel layout for operation.
(f) Aerodynamics.
(g) Tunnel safety.
(h) Drainage.
(j) Optimal data flow.
(k) Mechanical equipment.
(l) 50 Hertz devices.
(m) Electrical power supply.
(n) Design of access to the operation facilities.
2. Construction Contract
(a) Introduction of NATM-relevant standards and guidelines
(b) Presentation and discussion of different construction contract models and
their application
(c) Structure of construction contracts
(d) Practical execution of contracts
3. Instrumentation, Monitoring, Data Evaluation and Interpretation
(a) Fundamentals of geotechnical measurement methods in tunnel construction.
(b) Design of measurement programmes.
(c) Selection of data.
(d) Data flow.
(e) Precondition for geotechnical measurements.
(f) Measuring instruments and their functions.
(g) Installation of measuring targets and instruments.
(h) Execution of geotechnical measurements.
(j) Processing of measurement data.
(k) Large scale tests and their instrumentation.
(l) Analysis of geotechnical measurement data.
(m) Comparison of geotechnical measurement results with calculation results
during the design.
(n) Interpretation of geotechnical measurement results.
(o) Use of measurement results for the prediction of ground quality.
(p) Use of measurement results for the estimate of lining loads.
4. Conventional and Mechanical Excavation Techniques including basics in TBM-
Tunnelling
(a) Explosives chemistry.
 (b) Explosives production (plant mixing / site mixing).
(c) The properties of explosives.
(d) Firing methods.
(e) Tunnelling blast design.
(f) Blasting emissions prognosis and measurements.
(g) Geotechnical definitions, laboratory tests and site investigations for road
headers.
(h) Rock testing in detail and operating data assessment for road headers.
(j) Cutting tests done on test rigs and cutting simulations done on computer.
(k) Machine prototype testing and machine optimization.
(l) Laboratory visit in Zeltweg.
(m) Rock mass cuttability rating in detail.
(n) Today’s cutting limits referring to road-header application.
(o) Detailed tunnelling project study.
(p) Tunnelling road-headers - product overview and details.
(q) Infrastructure and job site layout for road-header application.
(r) Exemplary excavation cost calculation for road-header operation.
(s) Operational reports of road-header applications.
(t) Tunnel boring machines - an overview.
(u) Penetration models for TBMs.
(v) Cutter wear prognosis.
(w) Basics in segmental lining design.
Ground Improvement
1. Grout Injection
(a) Grout types and theology.
(b) Limited mobility grouting.
(c) Cement grouting in rock.
(d) Permeation grouting of soils.
(e) Limited mobility grouting.
(f) Jet grouting.
(g) Pre-excavation grouting in rock tunnelling.
(h) Anchors and micro-piles.
(j) Deep mixing and diaphragm walls.
(k) Crisis management - massive inflows.
(l) Instrumentation.
(m) Case histories.
2. Artificial Ground Freezing
(a) Objectives and applications.
(b) Design considerations.
(c) Case histories.
Sub-divided into 05 modules as under :-
1. Module 1
(a) Introduction to NATM.
(b) Rock Mass classification and characterization.
(c) Investigation and exploration.
(d) Tunnel Design.
(e) Laboratory Tests.
2. Module 2
(a) Geotechnical Design.
(b) Tunnel Layout (Part-I).
3. Module 3
(a) Tunnel Layout (Part-II).
(b) Risk Analysis and Management.
(c) Site installations.
(d) Site organization and construction management.
4. Module 4
(a) Monitoring, Data interpretation and Safety management plan.
(b) Instrumentation for monitoring.
(c) Construction Contracts.
5. Module 5
(a) Excavation by drill, blasting and road-header.
(b) Basics of TBM.