Hard Rock Tunnel Boring Vol. 6 - Performance Data and Back-Mapping

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Hard Rock Tunnel Boring Vol. 6 - Performance Data and Back-mapping
Thesis · November 2000

DOI: 10.13140/RG.2.1.4674.1924
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Performance Data and Back-mapping
Hard Rock Tunnel Boring
Doctoral theses at NTNU 1998:81
Amund Bruland
Vol. 6 of 10
NTNU Trondheim
Norwegian University of
Science and Technology
Doctoral thesis
for the degree of doktor ingeniør
Faculty of Engineering Science
and Technology
Department of Civil and
Transport Engineering
PREFACE 1
0 GENERAL 3
0.1 Project Reports about Hard Rock Tunnel Boring 3
0.2 Field Performance Studies 6
1 MACHINE PERFORMANCE 8
1.0 Introduction 8
1.1 Net Penetration Rate 9
1.2 Gross Thrust 12
1.3 Torque 14
1.4 Machine Utilisation 15
1.5 Weekly Advance Rate 20
1.6 Parameter Summary 22
2 CUTTER CONSUMPTION 23
2.0 Introduction 23
2.1 Consumption per Position 24
2.2 Instantaneous Consumption 28
2.3 Ring Wear 34
3 PENETRATION TESTS 40
3.1 Test Procedure 40
3.2 Penetration Curve 44
3.3 Cutter Coefficient 47
3.4 Specific Energy 50
4 CHIP ANALYSIS 51
4.1 Test Procedure 51
4.2 Chip Size 54
4.3 Sieve Curve 58
4.4 Kerf Depth Factor 59
4.5 Crack Growth 61
4.6 Rock Properties 62

5 BACK-MAPPING 64
5.0 Introduction 64
5.1 Mapping Procedures 65
5.2 Aggregation of Mapping Data 71
5.3 Rock Sampling 77
5.4 Achieved vs. Predicted Performance 78
APPENDICES 79
A. Previous Editions 79
B. Research Partners 80
C. List of Parameters 81
D.1 Mapping Sheet ±135° 86
D.2 Mapping Sheet ±180° 87
D.3 Shift Log 88
D.4 Cutter Change Log 89
D.5 Sieve Curve Sheet 90
E. Penetration Test Spreadsheet 91

PREFACE
HARD ROCK TUNNEL BORING Performance Data and Back-mapping

Project Report 1E-98
The report is one of six reports about hard rock tunnel boring:
• 1A-98 HARD ROCK TUNNEL BORING Design and Construction

• 1B-98 HARD ROCK TUNNEL BORING Advance Rate and Cutter Wear
• 1C-98 HARD ROCK TUNNEL BORING Costs
• 1D-98 HARD ROCK TUNNEL BORING Geology and Preinvestigations
• 1E-98 HARD ROCK TUNNEL BORING
Performance Data and Back-mapping
• 1F-98 HARD ROCK TUNNEL BORING The Boring Process
In addition, HARD ROCK TUNNEL BORING Background and Discussion gives

general information about the basis of the above listed reports.
Combined with the other reports in the Project Report Series from the Department of
Building and Construction Engineering at NTNU, the reports present an updated and
systematised material on rock excavation and tunnelling to be used for:
• Economic dimensioning
• Choice of alternative
• Time planning
• Cost estimates, tender, budgeting and cost control
• Choice of excavation method and equipment.
A list of available Project Reports may be requested from the Department of Building
and Construction Engineering at NTNU.
The advance rate, cutter wear and excavation cost models also exist as a WINDOWS
programme.
The report is prepared by Amund Bruland and is part of his dr.ing thesis about
hard rock tunnel boring.
1
PREFACE
The reports listed above describes a comprehensive model developed at NTNU The
model covers the complete tunnel boring process from the early planning stage
through preinvestigations, time and cost estimates, tunnel excavation and finally ac-
quisition and treatment of experience data. The models and data presented in the
reports are meant to be a practical tool for owners, consultants and contractors,
more than a theoretical analysis of the tunnel boring process.
The project has been granted financial support by our external research partners, see
list in Appendix.
For reference, registration and similar, we ask for the following:
NTNU-Anleggsdrift (1998): Project Report 1E-98 HARD ROCK TUNNEL

BORING Performance Data and Back-mapping.
When copying from the report, the source should be stated.
Trondheim, September 2000
Odd Johannessen
Professor
Contact address: Amund Bruland

Department of Building and Construction Engineering, NTNU
N-7491 Trondheim
NORWAY
Telephone +47 73 59 47 37 Fax +47 73 59 70 21

e-mail amund.bruland@bygg.ntnu.no
Internet http://www.bygg.ntnu.no/batek/batek.htm
2
0. GENERAL 0.1 Project Reports about Hard Rock Tunnel Boring
0.1 PROJECT REPORTS ABOUT HARD ROCK TUNNEL BORING
1E-98
The report provides methods and data to be used during follow-up and analysis of
TBM performance and for back-mapping of engineering geological properties of
bored tunnels.
The report treats the following items:
• Chapter 1 describes a system for recording, averaging and normalisation of ma-

chine performance data such as net penetration rate, gross advance rate, machine
utilisation, etc.
• In Chapter 2, methods for recording and analysis of the cutter wear of individual
cutters and the cutterhead as a whole are presented.
• Chapter 3 describes how to perform and analyse penetration tests.
• Various measurement procedures and how to analyse the rock breaking process
using the largest chips are treated in Chapter 4.
• Procedures for engineering geological back-mapping and normalisation of map-
ping data are described in Chapter 5.
Project Report 1E-98 is partly based on the project reports 1-76, 1-79, 1-83, 1-88 and
1-94, all published by the Department of Building and Construction Engineering at
NTNU. The report presents updated and revised information from the previous re-
ports as well as experience from recent tunnelling projects.
Appendix A shows a list of previous editions of the HARD ROCK TUNNEL

BORING report.
Other Reports
The Project Report 1A-98 HARD ROCK TUNNEL BORING Design and Con-
struction describes general design parameters such as tunnel profile, tunnel inclina-
tion and curve radius. Some features of various tunnel types like water, sewage, road
3
and rail tunnels are treated. Transport, ventilation and other necessary service systems
are presented.
The Project Report 1B-98 HARD ROCK TUNNEL BORING Advance Rate and
Cutter Wear provides methods and necessary data for estimation of time consump-
tion and cutter wear for tunnel boring. Geological parameters and machine factors of
significance for the penetration rate and the cutter wear are presented briefly.
The Project Report 1C-98 HARD ROCK TUNNEL BORING Costs presents
models and data for estimation of tunnel excavation costs and total construction costs.
The Project Report 1D-98 HARD ROCK TUNNEL BORING Geology and Site
Investigations treats the rock mass parameters of the model in more detail. Site
investigations and building of an engineering geological model adapted to the estima-
tion models for penetration rate and excavation costs are treated closely.
Project Report 1F-98 HARD ROCK TUNNEL BORING The Boring Process
covers rock breaking and chipping, machine factors affecting performance, boring in
fractured rock mass, and various topics of cutter wear.
Use of the Estimation Models
The estimation models are aimed at being used through several stages in a project:
• Preliminary and feasibility studies

• Project design and optimisation
• Tendering and contract
• Construction
• Possible claims.
The estimation models for Hard Rock Tunnel Boring should be used with care. Com-
bined with other estimation models in the Project Report Series from the Department
of Building and Construction Engineering, the Hard Rock Tunnel Boring reports pro-
vide a reliable and practical tool to be used for:
4
• Estimating net penetration rate and cutter wear

• Estimating time consumption and excavation costs, included risk
• Assess risk with regard to variation in rock mass boreability or machine
parameters
• Establish and manage price regulation in contracts
• Verify machine performance
• Verify variation in geological conditions.
Background
The estimation models are based on job site studies and statistics from tunnelling in
Norway and abroad, including more than 35 job sites and more than 250 km of tunnel.
The data have been systematised and normalised. The results are regarded as being
representative for well organised tunnelling.
A more detailed treatment of the background and the basis for the Hard Rock Tunnel
Boring estimation models is found in HARD ROCK TUNNEL BORING Back-
ground and Discussion.
5
0. GENERAL 0.2 Field Performance Studies
0.2 FIELD PERFORMANCE STUDIES
The performance data of the machine are combined with the cutter wear data and data
from the engineering geological back-mapping to be able to evaluate the performance
of the tunnel excavation with regard to the geological conditions along the tunnel.
Field performance studies at a TBM tunnel aim to provide information and knowl-
edge to be used for several purposes:
• To improve the tunnel boring operations at the site.

• To verify the tunnelling performance against the models and assumptions used in
the planning process.
• To increase the knowledge and expertise of the tunnelling organisation.
• To provide data for further development of the TBM and tunnelling technology in
general.
• To provide data for development and improvement of the general prediction mod-
els related to TBM tunnelling, to be used by planners, contractors, manufacturers,
etc.
The field performance studies should build a database that describes the geology and
the tunnelling performance by numbers. Each record of the database should represent
tunnel sections with approximately constant basic parameters, e.g. rock type, tunnel
direction, cutter thrust, cutterhead RPM. An example of sectioning of the database is
shown in Figure 0.1.
Z o n e 1 Z o n e 2 Z o n e 3
G e o lo g y
R a n g e 1 R a n g e 2 R a n g e 3 R a n g e 4 T B M
p a ra m e te rs
R a n g e 1 R a n g e 2 R a n g e 3 R a n g e 4 R a n g e 5 P e n e tr a tio n
ra te
R a n g e 1 R a n g e 2 C u tte r
c o n s u m p tio n
R e c o rd
1 2 3 4 5 6
D a ta b a s e
Figure 0.1 Sectioning of the back-mapping and follow-up database.

6
0. GENERAL 0.2 Field Performance Studies
In this process, the geology and the machine performance are related to the chainage
along the tunnel. Hence, an accurate and close marking of the chainage is recom-
mended, e.g. with minor indicators at each metre and major indicators at each 10 me-
tres.
Furthermore, the performance data and the geological back-mapping are normalised
and included in the general database of hard rock tunnel boring to form the basis for
improving and extending the prediction models for time and cost estimates of TBM
tunnelling.
The data collection and the development of the prediction models is a more or less
continuous process since the models are purely empirical and new input in the form of
e.g. machine design, cutter material and geological conditions is constantly available.
The field performance studies and data collection described in this report are consis-
tent with the basic follow-up program performed by the Department of Building and
Construction Engineering at NTNU at various tunnel boring sites. At a given tunnel
project, it will often be of interest, or even necessary, to perform additional or more
detailed observations and analyses of selected processes, equipment, parameters or
similar.
When planning and performing the follow-up of a specific tunnelling project, one
should keep in mind that detailed studies will get an increased value if combined with
general follow-up as described in Sections 1.0, 2.0 and 5.0 of this report.
7
1. MACHINE PERFORMANCE 1.0 Introduction
1.0 INTRODUCTION
The machine performance is continuously recorded through the shift logs and/or log
files from the onboard computer.
Specific tests such as penetration tests give valuable and more detailed information
about the machine performance.
The logs should as a minimum provide data to be able to calculate the instantaneous
and average of:
• Net penetration rate (mm/rev and m/h)

• Applied cutter thrust (kN/cutter)
• Torque (kNm) and cutter coefficient
• Machine utilisation (%)
• Gross advance rate (m/week).
An example of a shift log is given in Appendix D.
8
1. MACHINE PERFORMANCE 1.1 Net Penetration Rate
1.1 NET PENETRATION RATE
The average net penetration rate is calculated based on systematic and continuous
recording of the chainage and the machine hours, recorded e.g. at the end of each
shift. For the accuracy of the records it is important that the machine hour meter
measures boring hours. Hence, it must only be activated by a combination of cutter-
head rotation and cutterhead thrust.
It is convenient to base the follow-up work on the average net penetration rate over
one shift, see Figure 1.1. When an onboard computer is used for data acquisition and
logging, shorter intervals like the stroke length may be used when the average net
penetration rate is calculated. The penetration rate calculated from the logging system
(shift log or computer) should be verified by penetration rate measurements, e.g. over
one stroke length.
m/h
0
2450 2460 2470 2480 2490 2500
Chainage, m
Figure 1.1 Net penetration rate at the Meraaker Project, calculated from shift logs.
dtbm = 3.5 m. Courtesy of NCC Eeg-Henriksen Anlegg AS and Veidekke
ASA.
The detailed net penetration records are compared to the engineering geological back-
mapping at a detailed level. Figure 1.1 may be explained as follows:
9
• The relative high net penetration rate from chainage 2450 to 2460 and from chain-
age 2490 to 2500 may have various reasons, of which the most likely are:
♦ Higher average cutter thrust

♦ Higher degree of fracturing
♦ Influenced by a Marked Single Joint
♦ Weaker rock type
The average penetration rate must be calculated using the total machine hours used to
bore the actual tunnel length, and not as an arithmetical average of the penetration
rates of the subsections (e.g. shifts) constituting the actual tunnel length.
Im =
∑l j
=
∑l j
(m/h) [1.1]
∑T bj ∑ (l j / I nj )
Im = average net penetration rate (m/h)

Inj = net penetration rate for subsection j (m/h)
lj = length of subsection j (m)
Tbj = net time (machine hours) used to bore subsection j (h)
It is convenient to average the net penetration rate over time periods of equal length
(e.g. weeks, see Figure 1.2) or over tunnel sections, each section with more or less
constant geological conditions.
10
9
m/h
8
Cumulated average
7
0
38 42 46 50 2 6 10 14 18 22 26 30 34
Week no. of 1991/1992
Figure 1.2 Average net penetration rate at the Meraaker Project, calculated from
shift logs. dtbm = 3.5 m, Lt = 10 km. Courtesy of NCC Eeg-Henriksen
Anlegg AS and Veidekke ASA.
11
1. MACHINE PERFORMANCE 1.2 Gross Thrust
1.2 GROSS THRUST
The prediction model in the Project Report 1B-98 HARD ROCK TUNNEL
BORING Advance Rate and Cutter Wear uses the gross average thrust per cutter
as a measure for the applied cutter force. Gross average thrust means:
• The total gross thrust is the gross thrust force from the thrust or propel cylinders,
including friction or drag of the cutterhead and the cutterhead support system and
other losses of thrust.
• The total gross thrust is divided by the number of cutters on the cutterhead to get
the gross average thrust per cutter.
The above system is meant to simplify and standardise the data acquisition and treat-
ment. Individual and net cutter forces are very difficult to measure and will introduce
additional uncertainty in the performance data analyses and in the prediction model.
It may however be necessary to instrument individual cutters to measure the cutter

forces for research and development purposes.
The applied gross thrust is calculated from the applied hydraulic pressure in the pro-
pel cylinders, as shown in Section 3.2, Equation [3.5].
The applied hydraulic pressure is recorded continuously by the onboard computer or

at regular intervals in the shift log by readings of the propel pressure gauge. The shift
log should record the propel pressure at least two times during one stroke length.
The applied thrust will oscillate somewhat. Since the prediction model for net pene-
tration rate is based on the applied gross average cutter thrust, it is important to use
the average reading of the pressure gauge and not the maximum deflection of the
pointer.
When the applied thrust is averaged over a given tunnel length, the instantaneous
thrust is weighted by time.
M Bm =
∑ (M ⋅ T
Bj bj )
(kN/cutter) [1.2]
∑T bj
12
1. MACHINE PERFORMANCE 1.2 Gross Thrust
MBm = gross average thrust over a given tunnel length (kN/cutter)

MBj = gross average thrust over subsection j (kN/cutter)
Tbj = net time in machine hours for boring subsection j (h)
lj
Tbj = (h) [1.3]
I nj
lj = length of subsection j (m)

Inj = net penetration rate of subsection j (m/h)
The gross thrust should be averaged over the same time periods and tunnel sections as
the net penetration rate.
13
1. MACHINE PERFORMANCE 1.3 Torque
1.3 TORQUE
The applied torque TB is calculated from the applied amperage of the cutterhead drive
motors. Equation [1.4] is applicable for 3-phase motors.
U B ⋅ I B ⋅ 3 ⋅ (cos φ ⋅ η ) ⋅ 60 ⋅ nm
TB = (kNm) [1.4]
2 ⋅ π ⋅ 1000 ⋅ RPM
UB = applied operating voltage of the cutterhead drive motors (V)

IB = applied amperage (A)
cosφ⋅η = efficiency of the motors at the given amperage, see Section 3.3
(if unknown, cosφ⋅η = 0.8 is a good approximation)
nm = number of motors on the cutterhead
RPM = cutterhead revolutions (rev/min)
The applied amperage is recorded continuously by the onboard computer or at regular

intervals in the shift log by readings of the ampere meters. The shift log should record
the amperage at least two times during one stroke length.
The applied amperage will oscillate somewhat. Since the prediction model for neces-
sary torque is based on the average amperage, it is important to use the average read-
ing of the ampere meter and not the maximum deflection of the pointer.
When the applied amperage is averaged over a given tunnel length, the instantaneous
amperage is weighted by time.
I Bm =
∑ (I ⋅ T
Bj bj )
(A) [1.5]
∑T bj
IBm = average amperage over a given tunnel length (A)

IBj = amperage over subsection j (A)
Tbj = net time for boring subsection j (h), see also [1.3]
The amperage should be averaged over the same time periods and tunnel sections as
the net penetration rate.
14
1. MACHINE PERFORMANCE 1.4 Machine Utilisation
1.4 MACHINE UTILISATION
The machine utilisation is defined as the boring time in percent of the total available
shift or working hours. The machine utilisation is calculated for given time periods
(e.g. week, month) or for given tunnel sections (e.g. geological zones, total tunnel
length).
The calculation of the machine utilisation is entirely based on data from the shift logs
recorded by the TBM operator. In some cases, it is difficult to state the appropriate
cause of stop in the boring. In the future, use of the onboard computer for semiauto-
matic data recording and treatment will improve the reliability and objectivity of the
shift log data. A digital shift log will also improve the possibilities and the results of
back-analyses of the machine performance.
The shift log records:
• Chainage and machine hours.

• Basic machine operation parameters (applied thrust, torque and cutterhead RPM,
if variable).
• Time consumption of main activities.
• Main causes of stops in the boring.
An example of a well-suited shift log for hard rock tunnel boring is shown in Appen-
dix D. The grouping of the activities may vary, but the following is recommended to
be included in the main activities:
• Boring, including regripping Tbr

• Cutter change and inspection Tc
• Repair and service of the TBM Ttbm
• Repair and service of the backup equipment Tbak
• Muck transport (if separate transport system such as continuous conveyor) Tmt
• Other transport (personnel, equipment, materials) Tot
• Supply of water, electricity and ventilation Tw
• Surveying Ts
• Personal time such as travel, change of crews, lunch breaks, etc. Tp
• Rock support, water inflows and other geological stop causes Trs
• Other activities Toa
15
The main activities may be subdivided into even more specific activities such as for
rock support in a continuously lined tunnel in weak and water-bearing rock mass.
♦ Rock support
• Probe drilling
• Pregrouting
• Segment erection
• Back-filling of the segmental lining
• Water inflow
• Other rock support.
One must however remember that the shift log is recorded by the TBM operator who
normally gives priority to the tunnel excavation operations. Hence, to ensure the qual-
ity of the recorded data, the shift log must not be too complex asking detailed infor-
mation of little relevance.
The causes of stops in the boring may be entered as comments if necessary.
It is not convenient to record boring and regripping separately in the shift log. When
calculating the machine utilisation, one has to combine the recorded machine hours
(net boring time) and the recorded time consumption of boring, including regripping
as shown in [1.6] and [1.7]. The equations are based on a time period of one week.
Tb = t 2 − t1 (h /week ) [1.6]
Tb = net time for boring (h/week)

t1 = machine hours at the start of the actual week (h)
t2 = machine hours at the end of the actual week (h)
Tr = Tbr − Tb (h /week ) [1.7]
Tr = time for regripping (h/week)

Tbr = time for boring, including regripping, per week, from the shift log
(h/week)
16
To be able to compare the achieved machine utilisation with the normalised model in
Project Report 1B-98 HARD ROCK TUNNEL BORING Advance Rate and
Cutter Wear, the time consumption for rock support work is excluded from the total
working hours to make up the available excavation time. The reason for this is that
the type and amount of rock support work is mainly dependent on the site geology
and much less by the tunnel boring system.
Tex = Tsh − Trs (h /week ) [1.8]
Tex = available time for tunnel excavation (h/week)

Tsh = shift hours (h/week)
Trs = time for rock support work (h/week)
Tb I u ⋅ 100
ua = = (%) [1.9]
Tex I n ⋅ Tex
ua = achieved machine utilisation per week (%)

Tb = time for boring (h/week)
Iu = weekly advance rate (m/week)
In = average net penetration rate per week (m/h)
The utilisation must also be corrected for weekly working hours (shift hours) other
than 100 h/week.
Tsh
un = ua ⋅ (%) [1.10]
Teh
un = normalised machine utilisation per week of 100 shift hours (%)

Teh = effective working hours (h/week)1
Tsh = shift hours (h/week)
1
Figure 4.2 in Project Report 1B-98 HARD ROCK TUNNEL BORING Advance Rate and Cutter
Wear.
17
An example of a plot of the weekly machine utilisation and cumulated machine utili-
sation is shown in Figure 1.3.
70
%
60
50 Cumulated average
40
30
20
10
0
38 42 46 50 2 6 10 14 18 22 26 30 34
Week no. of 1991/1992
Figure 1.3 Machine utilisation at the Meraaker Project. dtbm = 3.5 m, Lt = 10 km.
Courtesy of NCC Eeg-Henriksen Anlegg AS and Veidekke ASA.
The cumulated average machine utilisation for a given tunnel length or period of time
is calculated directly from the cumulated time consumption for the given period as in
[1.11]. If the weekly working hours varies from week to week, the cumulated utilisa-
tion may be calculated by [1.12], where the utilisation is weighted by working hours
per week. Non-productive stops like vacations are not included in the cumulated av-
erage.
um = ua =
∑T b
⋅ 100 (%) [1.11]
∑T ex
um =
∑ (u a ⋅ Tsh ) (%) [1.12]
∑ Tsh
18
The total use of time distributed on the various tunnelling operations may be illus-
trated by pie charts as the example in Figure 1.4.
Other 4.6
Water etc. 10.0
Transport 9.7 Boring 40.2
Backup 4.1
TBM 5.4
Cutters 15.3
Regripping 10.7
Figure 1.4 Tunnelling time consumption in per cent distributed on various opera-
tions at the Meraaker Project. dtbm = 3.5 m, Lt = 10 km, Im = 6.4 m/h.
19
1. MACHINE PERFORMANCE 1.5 Weekly Advance Rate
1.5 WEEKLY ADVANCE RATE
450
m/week
400
350 Cumulated average
300
250
200
150
100
50
0
38 42 46 50 2 6 10 14 18 22 26 30 34
Week no. of 1991/1992
Figure 1.5 Weekly advance rate at the Meraaker Project. dtbm = 3.5 m, Lt = 10 km.
The cumulated average weekly advance for a given tunnel length or period of time is
calculated directly from the bored tunnel length and the number of productive weeks
in the period. The cumulated average may also be calculated by the cumulated aver-
ages as in [1.14].
l 2 − l1
Iu = (%) [1.13]
nu
l1 = chainage at the start of the period (m)

l2 = chainage at the end of the period (m)
nu = number of productive weeks of the period
20
1. MACHINE PERFORMANCE 1.5 Weekly Advance Rate
I u = u m ⋅ Tex ⋅ I m (m/week) [1.14]
To be able to compare the achieved weekly advance rate with the normalised model
in Project Report 1B-98 HARD ROCK TUNNEL BORING Advance Rate and
Cutter Wear, the advance rate must be related to 100 working hours available for
tunnel excavation per week, and also be corrected for weekly working hours (shift
hours) other than 100 h/week.
Tsh
I un = u m ⋅ 100 ⋅ I m ⋅ (m/week) [1.15]
Teh
21
1. MACHINE PERFORMANCE 1.6 Parameter Summary
1.6 PARAMETER SUMMARY
It is convenient to aggregate the detailed information from the shift logs into a more
readable form. A visual presentation as shown in Figure 1.6 gives a quick and very
informative overview of the operation of the machine, as well as providing a basis for
analyses of the machine performance with regard to the engineering geological back-
mapping.
The aggregated performance data are also a good check for large errors in the back-
mapping. It is however not recommended to bring the summary into the tunnel while
performing the back-mapping. This may bias the classification of the rock mass de-
gree of fracturing or other parameters of the mapping.
5
N e t p e n e tr a tio n r a te , m /h
2 5 0
T h ru s t, k N /c u tte r
2 0 0
1 5 0
2 5 0
T o rq u e , A
2 0 0
1 5 0
2 4 5 0 2 4 6 0 2 4 7 0 2 4 8 0 2 4 9 0 2 5 0 0
C h a in a g e , m
Figure 1.6 Summary of averaged machine performance parameters over shifts,

based on data from the shift logs.
22
2. CUTTER CONSUMPTION 2.0 Introduction
2.0 INTRODUCTION
The cutter consumption is recorded through the cutter change and inspection log in
the tunnel and the cutter repair log at the cutter shop. Specific tests such as the wear
progress of specific cutter rings and positions, steel quality measurements, etc., give
valuable and more detailed information about the cutter wear process.
The logs should as a minimum provide data to be able to compute:
• Instantaneous and average cutter wear for the cutterhead (h/c, m/c and sm3/c)
• Cutter consumption for each cutter position (e.g. no. of rings)
• Reason for change (e.g. ring wear, oil leakage, blocked bearings)
• Type and extent of the wear of each ring
• Consumption of spare parts.
To be able to trace the individual cutter and record the necessary data for the above-
mentioned calculations, each cutter must have a unique identity, e.g. a number. The
cutter change log must be related to the tunnel chainage and the machine hours.
An example of a cutter change log is given in Appendix D.
If swapping of partly used cutters between positions (e.g. from outer to inner gauge)
is done, this must be noted in the cutter change log and corrected for in the calcula-
tions of the cutter consumption.
To be able to calculate the instantaneous consumption towards the end of the tunnel,
one should record the wear state of all cutters when the boring is finished. The state is
recorded as wear height or as a rough estimate of remaining ring life in per cent. If the
boring of the tunnel starts with partly used cutter rings, the wear state of the cutters
should be recorded at the start of the boring in the same way.
23
2. CUTTER CONSUMPTION 2.1 Consumption per Position
2.1 CONSUMPTION PER POSITION
The cutter consumption per position is used to:
• Evaluate the cutterhead design, e.g. with regard to placement of the individual
cutter.
• Calculate the cutterhead factor fD and the correction factor for TBM diameter with
regard to cutter consumption, see Figure 3.2 of Project Report 1B-98 HARD
ROCK TUNNEL BORING Advance Rate and Cutter Wear.
35
No. of rings used
Other
30 Chipped ring
Oil leakage
Blocked
25
Wear
20
15
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Cutter position no.
Figure 2.1 No. of rings used per cutter position at the Meraaker Project. dtbm = 3.5
m, Lt = 10 km, Ntbm = 25. Courtesy of NCC Eeg-Henriksen Anlegg AS
and Veidekke ASA.
Figure 2.1 shows two important features of the given cutterhead design:
• The positions 12 through 17 are exposed to the highest loads, indicated by the
number of cutters replaced for reasons other than wear. The load of the cutters
may be reduced by adding one cutter in this area (if possible).
24
• The centre cutter positions no. 2 and 4 should be examined to find a better design,
indicated by the number of cutters replaced for reasons other than wear. In the ac-
tual tunnel, the positions could be relieved by replacing the cutter in position 5
more often.
The cutterhead factor is calculated by normalising the cutter ring consumption per
position to a cutterhead with radius 1 and an average cutter consumption of 1 ring per
position as shown below.
Ni
rri = [2.1]
N tbm
rri = relative radius of cutter position no. i

Ni = cutter position no. i
Ntbm = number of cutter positions on the cutterhead
H ri =
∑ H ni [2.2]
N tbm ⋅ H ni
Hri = relative cutter ring life of position no. i

Hni = number of cutter rings used at position no. i
fD =
∑H ri
[2.3]
N tbm
fD = cutterhead factor
fD
kD = [2.4]
f D0
kD = correction factor for TBM diameter with regard to cutter ring life
fD0 = 1.133, i.e. the cutterhead factor of the reference cutterhead
(dtbm = 3.5 m, dc = 394 mm, Ntbm = 27)
25
Position No. No. of Rings Used Relative Position Relative Life

1 11 0.04 1.8400
2 13 0.08 1.5569
3 11 0.12 1.8400
4 13 0.16 1.5569
5 12 0.20 1.6867
6 11 0.24 1.8400
7 11 0.28 1.8400
8 13 0.32 1.5569
9 14 0.36 1.4457
10 19 0.40 1.0653
11 22 0.44 0.9200
12 29 0.48 0.6979
13 33 0.52 0.6133
14 29 0.56 0.6979
15 30 0.60 0.6747
16 32 0.64 0.6325
17 28 0.68 0.7229
18 25 0.72 0.8096
19 25 0.76 0.8096
20 24 0.80 0.8433
21 22 0.84 0.9200
22 22 0.88 0.9200
23 21 0.92 0.9638
24 19 0.96 1.0653
25 17 1.00 1.1906
Total 506 28.7098
28.7098
Cutterhead factor fD = = 1.1484
25
1.1484
Correction factor for TBM diameter kD = = 1.01
1.133
Table 2.1 Calculation of cutterhead factor and correction factor for TBM diameter
with regard to cutter consumption. Data from Figure 2.1.
26
Table 2.1 shows the calculation of the cutterhead factor fD and the correction factor kD
for the data in Figure 2.1.
Figure 2.2 shows observed and normalised cutter replacement curves (relative cutter
life) for various TBM diameters. The integral of the curves gives the cutterhead fac-
tor.
6 .0
R e la tiv e c u tte r life
5 .0
4 .0
3 .0
2 .0
d tb m = 6 .5 m
1 .0 4 .5 m
3 .5 m
0 .2 0 .4 0 .6 0 .8 1 .0
R e la tiv e c u tte r p o s itio n
Figure 2.2 Normalised cutter replacement curves for varying TBM diameter.
27
2. CUTTER CONSUMPTION 2.2 Instantaneous Consumption
2.2 INSTANTANEOUS CONSUMPTION
The instantaneous cutter consumption along the tunnel is calculated between cutter
changes as illustrated in Figure 2.3. The figure shows the calculation model for cutter
wear in cutter/m. The same model is used to calculate cutter/h, simply by substituting
the chainage (in metres) for each cutter change with the corresponding machine
hours.
C h a in a g e
m 1 2 0 2 0 0 2 9 0 3 4 0 4 1 0
C h a n g e
n o .
1 2 3 4 5
N c
w 1 ,3 = 3 )
w 2 ,3 = w 1 ,3 w 3 ,3 = w 1 ,3 w 4 ,3 = N /A
3
i
C u tte r p o s itio n , N
w 1 ,2 = 2 )
w 2 ,2 = w 1 ,2 w 3 ,2 = N /A w 4 ,2 = N /A
2
w 1 ,1 = 1 ) w 2 ,1 = 4 ) w 3 ,1 = 5 ) w 4 ,1 = w 3 ,1
3
T o ta l 3 3 w = å w 3
m 3 3 ,i
w e a r w m 1 = å w 1 ,i= 0 .0 2 2 9 w m 2 = å w 2 ,i= 0 .0 2 1 5 i= 1 w m 4 = å w 4 ,i= N /A
i= 1 i= 1 i= 1
[c /m ] = N /A
T o ta l 1 1
life H m 1 =
w
= 4 3 .6 7 H m 2 =
w
= 4 5 .5 1 H m 3 = N /A H m 4 = N /A
m 1 m 2
[m /c ]
1 0 0 2 0 0 3 0 0 4 0 0
C h a in a g e , m
S ta r t b o r in g
1 ) 1 3 ) 1 5 ) 1
w 1 ,1 = = 0 .0 1 2 5 c /m w 1 ,3 = = 0 .0 0 4 5 c /m w 3 ,1 = = 0 .0 0 8 3 c /m
2 0 0 -1 2 0 3 4 0 -1 2 0 4 1 0 -2 9 0
2 ) 1 4 ) 1
w 1 ,2 = = 0 .0 0 5 9 c /m w 2 ,1 = = 0 .0 1 1 1 c /m
2 9 0 -1 2 0 2 9 0 -2 0 0
= c u tte r p o s itio n r e p la c e d
Figure 2.3 Calculation of cutter consumption in cutter/m for a theoretical cutter-

head with three cutters.
28
It must be noted that the terms cutter wear, cutter consumption, cutter/m and cutter/h
refer to the consumption of cutter rings only, and not of complete cutter assemblies.
The minimum requirements to the cutter change log are that it shows the following
for each cutter change:
• Cutter position(s) replaced

• Chainage in metres
• Machine hours
Preferably, the cutter change log should include information on cutter identification,
reason for change, etc. See Appendix D.
The following definitions are recommended to avoid confusion:
Cutter change Defined as the operation of replacing one or more worn or

damaged cutters at a given chainage. Cutter change no. 1 is de-
fined as the start of the boring.
Cutter replacement Defined as the replacement of a worn cutter with a new or re-
built cutter (new ring as a minimum) at a single position during
a cutter change.
The basic concept used to calculate the cutter consumption based on the cutter change
logs is shown in Figure 2.3. The detailed model will not be treated here, but is avail-
able as a PC program from the Department of Building and Construction Engineering
at NTNU.
Table 2.2 shows the minimum necessary input data of the PC program as recorded in
the data file. "1" means that the position has been replaced at the actual cutter change
and "0" means no cutter replacement.
The data in Table 2.2 are from a tunnel bored in extremely hard and strong rock with
medium abrasivity. This is reflected in the frequent cutter changes and very low cutter
life shown in Tables 2.2 and 2.3 and in Figure 2.4.
29
Cutter Chainage Machine

Positions 1 - 25
Change No. (m) hours (h)
1 122.3 2186.5 1111111111111111111111111
2 164.4 2208.4 0000000000100000000000000
3 179.5 2214.4 1111100000011111111111100
4 181.7 2215.0 1010000000000000000000000
5 195.6 2223.1 0000000000001111111100000
6 219.0 2238.0 0000000000000011111100000
7 228.0 2242.8 0000000000001001000000000
8 232.6 2244.6 0000000000000111111111100
9 244.4 2252.2 0000000000000000010110000
10 265.0 2264.1 0000000000000111111110000
11 288.0 2277.1 0000000000000000011110000
12 297.8 2283.9 1111111111111111111111111
13 305.1 2290.4 0000000000000011111000000
14 311.1 2293.0 0000000000001000000100000
15 316.5 2296.8 0000000000000011100000000
16 325.0 2300.5 0000000000000001111111000
… … … …
Table 2.2 Data file for calculation of cutter consumption along the tunnel. TBM
with 25 cutters.
Table 2.3 and Figure 2.4 show results of the calculation of the instantaneous cutter
consumption based on the data in Table 2.2.
30
From To Interval
Hf Hh Hm wm Cutters % In Ic
Chainage Chainage 3 Length Ic /In
(m /c) (h/c) (m/c) (c/m) Changed Changed (m/h) (m/h)
Table 2.3
(m) (m) (m)
122.3 164.4 26.7 1.38 2.77 0.361 42.1 1 4 1.92 2.01 1.05
164.4 179.5 27.9 1.44 2.90 0.345 15.1 17 68 2.52 2.02 0.80
Table 2.2.
179.5 181.7 6.2 0.22 .65 1.544 2.2 2 8 3.67 2.91 0.79
181.7 195.6 14.8 .0.84 1.53 0.652 13.9 8 32 1.72 1.83 1.06
195.6 219.0 20.5 1.30 2.13 0.469 23.4 6 24 1.57 1.64 1.05
2. CUTTER CONSUMPTION
219.0 228.0 13.9 0.75 1.45 0.692 9.0 2 8 1.87 1.93 1.03
228.0 232.6 12.3 0.60 1.28 0.781 4.6 10 40 2.56 2.12 0.83
232.6 244.4 17.4 1.11 1.81 0.552 11.8 3 12 1.55 1.63 1.05
244.4 265.0 21.7 1.32 2.26 0.443 20.6 8 32 1.73 1.70 0.98
265.0 288.0 21.9 1.32 2.28 0.439 23.0 4 16 1.77 1.72 0.97
288.0 297.8 14.3 0.96 1.48 0.674 9.8 25 100 1.44 1.54 1.07
297.8 305.1 9.4 0.75 .98 1.022 7.3 5 20 1.12 1.31 1.17
305.1 311.1 13.7 0.81 1.43 0.700 6.0 2 8 2.31 1.76 0.76
311.1 316.5 14.9 0.84 1.55 0.646 5.4 3 12 1.42 1.85 1.30
316.5 325.0 14.9 0.76 1.55 0.646 8.5 7 28 2.30 2.04 0.89
Instantaneous cutter consumption along the tunnel, based on the data in

2.2 Instantaneous Consumption
31
In Table 2.3, Hf, Hh, Hm and wm are calculated according to Figure 2.2. In is the
achieved penetration rate calculated from the chainage and the machine hours.
l c ,i +1 − l c ,i
I n ,i = (m/h) [2.5]
hc ,i +1 − hc ,i
lc,i = chainage of cutter change no. i

lc,i+1 = chainage of cutter change no. i+1
hc,i = machine hours of cutter change no. i
hc,i+1 = machine hours of cutter change no. i+1
Ic is the theoretical penetration rate calculated from the cutter life in metres and in
hours between the actual cutter changes.
H m ,i
I c ,i = (m/h) [2.6]
H h ,i
Hm,i = calculated cutter life between cutter changes no. i and i+1 (m/cutter)
Hh,i = calculated cutter life between cutter changes no. i and i+1 (h/cutter)
The ratio Ic /In is used to evaluate the quality of the calculated cutter life. When Ic /In is
close to 1.0, the cutter wear situation has been normal. When Ic /In is substantially less
or larger than 1.0, it is an indication of:
• Abnormal wear of the cutters, e.g. blocked cutter(s). The low cutter life and Ic /In
ratio between chainages 179.5 and 181.7 is caused by two blocked cutters being
replaced at chainage 181.7, see Table 2.2.
• Irregular replacement of cutters, e.g. replacement of one or more positions before
the cutter ring is worn to its limit. The low Ic /In ratio between chainages 228.0 and
232.6 is caused by one cutter position being replaced at chainage 232.6 as part of a
larger series of neighbouring positions being replaced, see Table 2.2.
The ratio Ic /In should be used when deciding suitable rock sampling sites to compare
the calculated cutter life to geological parameters.
32
1.6
h/c
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
100 150 200 250 300 350
Chainage, m
Figure 2.4 Instantaneous cutter consumption along the tunnel, based on the data in
Table 2.2.
Figure 2.4 shows that the representative cutter life for the tunnel section until chain-
age 300 is at approximately 1.2 – 1.3 h/cutter.
33
2. CUTTER CONSUMPTION 2.3 Ring Wear
2.3 RING WEAR
Data on the ring wear process is used as a basis to evaluate and improve:
• The ring design and the ring steel

• The cutterhead design
• The cutter replacement pattern
• The boring process.
Wear data are collected at the cutterhead during cutter inspections or cutter changes.
The extra few minutes used to collect the wear data from selected cutter positions will
give valuable information.
Wear Height
The wear rate of the individual cutter ring is measured as loss of ring height, see Fig-
ure 2.5. The ring height should be measured at the cutterhead a few times during the
ring life for selected cutter positions, and for each replaced ring at the cutter repair
shop.
h o h o
h i h i
h r h r
0 0
Figure 2.5 Measurements of ring height.

h0 = height of new ring (mm)
hi = intermediate ring height measured at the cutterhead (mm)
hr = ring height at replacement (mm).
34
hwi = h0 − hi
(mm) [2.7]
hwr = h0 − hr
hwi = intermediate wear height at the cutterhead

hwr = wear height at time of replacement.
Figure 2.6 shows a typical wear progress of a face cutter ring of the constant cross
section type in very hard rock. The wear was measured at each stop for cutter inspec-
tion. The wear progress is typical for hard and strong rock, with a high wear rate for
new cutter rings (from machine hours 2242.8 to machine hours 2244.6). At machine
hours 2244.6 and 2264.1, one neighbour cutter position was replaced, resulting in a
lower wear rate until the next cutter change. Of cutter ring properties, the wear rate is
mainly dependent on the ring steel quality (e.g. measured as Rockwell C hardness)
and the cutter edge width.
35
mm 2283.9
30
2277.1
25
2264.1
20
15
2252.2
10
2244.6
5
2242.8
0
2240 2250 2260 2270 2280 2290
Machine hours, h
Figure 2.6 Wear progress of a cutter ring in a face position. dc = 483 mm.
In general, the cutter wear rate increases towards the gauge. Thus, the gauge positions
are equipped with wider rings than the face positions. The ring edge width is impor-
tant to record when the ring wear rate is analysed.
35
Figure 2.7 shows average wear height at cutter replacement, measured at the cutter
repair shop. The decreasing wear height towards the gauge is important to observe.
The main reason for less allowable wear in these positions is the need to maintain the
tunnel diameter for geometrical reasons. Furthermore, too large wear height in the
gauge will create poor conditions for the new gauge cutter rings when the boring is
resumed after the cutter change.
Position 20 in Figure 2.7 has very large wear height due to swapping of used cutters
from the outer gauge to this position. Hence, the cutters in this position have deliber-
ately been replaced very late.
45
mm
40
35
30
25
20
15
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Cutter Position
Figure 2.7 Average cutter ring wear height for the same TBM and tunnel as in Ta-
ble 2.2. Only cutters replaced due to wear are included.
Ring Steel Quality
The ring steel quality is measured as Rockwell C hardness (HRC). It is convenient to

use a hardness tester like Equotip1 or similar. The chemical composition of the steel is
usually not examined at the tunnel site.
1
Manufactured by PROCEQ SA, Switzerland.
36
The ring steel hardness should be measured over a cross section of the ring as shown
in Figure 2.8. Results of such measurements are shown in Figure 2.9. To do so, the
new ring has to be cut, which means that the hardness measurements will be quite
expensive and should be limited to a few rings. An alternative method is to measure
the hardness at the surface of the ring as shown in Figure 2.8, supplied with measure-
ments over the cross section of the ring for selected ring types.
Selected rings are measured as new rings at the cutter shop before they are mounted
on the hub and as used rings when the worn ring has been cut and removed from the
hub. When the hardness is measured on selected rings on the cutterhead, it is impor-
tant that the measurements at consecutive cutter inspections or changes are taken at
the same positions along the ring. This may be ensured by defining a known point at
the hub as starting point and take the measurements at given intervals along the ring.
M e a s u r e m e n ts o v e r th e c r o s s s e c tio n
6
M e a s u re m e n ts
o n th e r in g s u r fa c e
Figure 2.8 Measurement pattern for hardness measurements, with measurement

lines and points.
37
a 5 8 a 5 8
b 5 7 b 5 7
c 5 6 c 5 6
d 5 5 d 5 5
e 5 7 -3 7 e 5 4
f 3 5 f 5 3
5 0
5 0 4 9
4 9 4 8
5 2
4 8 5 1
4 7 4 6
4 6
4 5
4 4 4 5 4 4
Figure 2.9 Ring steel hardness (HRC) for two types of rings, measured over the
cross section according to Figure 2.8. The distance between measure-
ment points along the measurement lines was 7 mm.
Ring Wear Type
M u s h ro o m w id th C h ip p e d a r e a
E d g e w id th
M u s h r o o m in g C h ip p in g
Figure 2.10 Destructive wear types of cutter rings.
38
The ring wear should be abrasive, and not destructive. Destructive wear occurs in two
main types for steel ring cutters:
• Chipping along the cutter edge

• Mushrooming of the cutter edge.
Chipping along the cutter edge indicates that the steel hardness (or brittleness) is too
high with regard to the cutter thrust and/or the rock strength.
Mushrooming of the cutter edge indicates that the steel hardness (or brittleness) is too
low with regard to the cutter thrust and/or the rock strength.
Figure 2.11 Chipping of a cutter ring.
The chipping or mushrooming of the cutter edge is quantified as:
• Percentage of the ring circumference affected by the destructive wear

• The extra edge width due to mushrooming
• The typical length of individual chippings.
The measurements should apply to each side of the ring edge, denoted as inner and
outer side in relation to the cutterhead centre.
39
3. PENETRATION TESTS 3.1 Test Procedure
3.1 TEST PROCEDURE
The main purpose of a penetration test is to evaluate the machine performance in a

given geology. Hence, a penetration test should be followed by a detailed engineering
geological mapping of the actual tunnel section. In addition, the rock drillability
should be tested in the laboratory.
A complete penetration test consists of the following parts:
• Measurement of the cutterhead penetration over a given time at various thrust lev-
els and constant RPM.
• Registration of the average cutterhead torque of each cutter load level.
• Registration of other relevant data such as cutter wear state, whether the test is at
the start, middle or end of the stroke, cutterhead vibration level, etc.
• Measurement or registration of the net penetration rate, cutter thrust level and cut-
terhead torque of the previous and following strokes.
• Collecting a complete chip sample for the penetration test and chip samples for the
previous and following strokes.
Thrust levels
A penetration test should include at least four thrust levels. When deciding the thrust
levels Mt to be used, the current thrust level used by the operator is selected as the 100
% level, denoted as MB100. This presupposes that the machine is operated at an opti-
mum thrust level concerning net penetration rate, cutter life, cutterhead vibrations,
etc. The thrust levels of the test are then selected as:
M t1 ≈ 0.7 ⋅ M B100
M t 2 ≈ 0.8 ⋅ M B100
(kN/cutter) [3.1]
M t 3 ≈ 0.9 ⋅ M B100
M t 4 ≈ 1.0 ⋅ M B100
If applicable with regard to the cutter life, available torque, etc., it is recommended to
include a fifth thrust level in the test:
40
M t 5 ≈ 1.05 ⋅ M B100 (kN/cutter) [3.2]
The actual thrust levels are selected as rounded numbers to ease the operation of the
TBM during the test. If the machine in the given rock conditions is operated at a
thrust level corresponding to a cylinder pressure of pB100 = 217 bar, the actual thrust
levels are selected as follows:
p t1 = 160
p t 2 = 180
p t 3 = 200 (bar) [3.3]
p t 4 = 220
p t 5 = 230
To ensure the quality of the test, the operator must maintain a constant thrust level
during each step of the test. The applied thrust level must be recorded for each step of
the test, either as an observed average from the thrust cylinder pressure gauge or as a
printout from the onboard computer. The applied thrust must be averaged over time.
Test Duration
The penetration is measured over a time tt corresponding to approximately 30 revolu-

tions of the cutterhead at each thrust level. For small machine diameters, the penetra-
tion should be measured over at least tt = 3 minutes.
Before the measurement of the penetration starts, the operator must stabilise the thrust
at each level.
Penetration Measurement
The penetration it is measured in mm over the given time. It is recommended that the
penetration measurements are taken at one of the thrust cylinders since these are in
41
direct contact with the cutterhead. One may also use instruments at the operator con-
sole when the accuracy of such instruments has been verified.
Torque Measurement
The applied torque is recorded as the average amperage It for each step of the test,
either as an observed average of the ampere meters or as a printout from the onboard
computer. The applied amperage must be averaged over time.
The applied voltage of the cutterhead drive motors must be checked. The motors
should be operated at the rated voltage UN. Otherwise, the applied voltage of the test
Ut must be noted.
Test Data Example
Tunnel: Chainage: Date:

Average Applied Pressure Average Applied Amperage Penetration it for tt = 3 min
pt (psi) It (A) (mm)
2400 135 70
2700 175 97
3000 225 132
3300 250 169
RPM: 13.4 Comments: Average cutter wear. The test started right
after regripping.
Table 3.1 Example of data recorded during a penetration test. For further treat-
ment of the test, see Section 3.2
Previous and Following Strokes
It is recommended to measure the net penetration rate of the previous and following
strokes of the test stroke. This is done to ensure the quality and representativeness of
the test. The penetration rate should be measured over the complete strokes. For large
42
TBM diameters one may measure the net penetration rate only over parts of the stroke
length, e.g. for 20 - 30 minutes.
Personnel
At least two persons in addition to the TBM operator are needed to perform a penetra-
tion test with chip sampling: One for the penetration measurements and one for the
chip sampling.
43
3. PENETRATION TESTS 3.2 Penetration Curve
3.2 PENETRATION CURVE
The penetration curve in [3.4] is found by treatment of the observed data as shown
below.
b
M 
i 0 =  t  (mm/rev) [3.4]
 M1 
i0 = basic penetration (mm/rev)

Mt = gross average thrust of each thrust level (kN/cutter)
M1 = critical thrust to achieve a penetration of 1.0 mm/rev (kN/cutter)
b = penetration coefficient.
The data from Table 3.1 are modified to the data given in Table 3.2. The actual ma-
chine has Ntbm = 25 cutters and ntc = 2 thrust cylinders, each with an effective diame-
ter of dtc = 444.5 mm. The applied gross average thrust is calculated from the applied
cylinder pressure according to [3.5]. The basic penetration is found by [3.6].
π ⋅ d tc2 0.4536 ⋅ g
M t = p t ⋅ ntc ⋅ ⋅ ( p t in psi)
4 ⋅ 25.4 1000 ⋅ N tbm
2
(kN/cutter) [3.5]
p π ⋅ d tc2 1
M t = t ⋅ ntc ⋅ ⋅ ( p t in bar)
10 4 1000 ⋅ N tbm
pt = applied thrust cylinder pressure (psi or bar)

ntc = number of thrust cylinders
dtc = effective diameter of the thrust cylinders (mm)
g = gravitational constant = 9.81 (m/s2)
Ntbm = number of cutters on the cutterhead.
it
i0 = (mm/rev) [3.6]
RPM ⋅ t t
44
i0 = basic penetration (mm/rev)

it = penetration over the time tt (mm)
RPM = cutterhead rotation speed (rev/min)
tt = test duration time for one thrust level (min)
Gross Thrust Mt Basic Penetration i0 log10 Mt log10 i0

(kN/cutter) (mm/rev)
205.5 1.74 2.3128 0.2405
231.2 2.41 2.3640 0.3820
256.9 3.28 2.4098 0.5159
282.6 4.20 2.4512 0.6232
Table 3.2 Cutter thrust and basic penetration for a penetration test.
M1 and b in [3.4] are found by linear regression of the log10 values of the thrust and
the penetration. It is convenient to use a spreadsheet to perform the necessary calcula-
tions. An example of an EXCEL spreadsheet for this purpose is shown in appendix E.
The log10 values of Mt and i0 will usually fit very good to a straight line, see data of
Test 1 in Figure 3.1. The xy-plot of the log10 values should be analysed with regard to
which observations to include in the regression and the penetration curve. Test 2 is an
example of disturbed data, in this case a Marked Single Joint was found in the con-
secutive mapping of the actual tunnel section. Another cause of disturbance is too
large variation of the thrust during one or more steps of a test. When data of one or
two thrust levels are disturbed, the test may still be used for analyses, but with cau-
tion.
The linear regression of the log10 data results in the equation in [3.7]. The log10 ver-
sion of [3.4] is shown in [3.8]. The constants of the linear equation are transformed to
M1 and b according to [3.9] and [3.10].
log 10 (i 0 ) = AR ⋅ log 10 ( M t ) + B R [3.7]
AR = regression constant, see Appendix E

BR = regression constant, see Appendix E.
45
log 10 (i 0 ) = b ⋅ (log 10 ( M t ) − log 10 ( M 1 )) [3.8]
M1 is defined as the critical thrust to result in a penetration of 1.0 mm/rev. Hence, M1

is found by solving [3.7] for i0 = 1 mm/rev (log10(1) = 0).
BR
−
M 1 = 10 AR
(kN/cutter) [3.9]
b is found by setting [3.7] = [3.8] and substituting M1 with [3.9].
BR
−
b ⋅ (log 10 ( M B ) − log 10 (10 AR
)) = AR ⋅ log 10 ( M B ) + B R [3.10]
⇒ b = AR
log10 i0
Test 1
0.8 Test 2
Linear regression of Test 1
Linear regression of Test 2
0.6
0.4
0.2
0
2.3 2.35 2.4 2.45 2.5
log10 M t
Figure 3.1 Plot of log10 values of Mt and i0 for two penetration tests, including lin-
ear regression curves.
46
3. PENETRATION TESTS 3.3 Cutter Coefficient
3.3 CUTTER COEFFICIENT
The calculation of the cutter coefficient kc and the cutter constant cc is based on the
registrations of the applied amperage during the penetration test, see Table 3.1. The
use of electric motors is presupposed.
To be able to calculate kc, one needs the rated amperage IN and the efficiency curve
(cosφ⋅η) of the motors. An example of this is shown in Table 3.3 and Figure 3.2.
Applied Amperage Efficiency

cosφ η It /IN
It (A) cosφ⋅η
54 0.524 0.931 0.153 0.479
100 0.717 0.944 0.284 0.677
160 0.850 0.960 0.455 0.816
200 0.869 0.963 0.568 0.837
300 0.876 0.961 0.853 0.842
400 0.852 0.957 1.137 0.815
Table 3.3 Efficiency of an electric cutterhead drive motor with a rated power of
PN = 336 kW and a rated amperage of IN = 351.8 A. The necessary data
are usually found in the Service and Operation Manual of the machine.
The cutter coefficient is calculated according to [3.11].
U t ⋅ I t ⋅ 3 ⋅ (cos φ ⋅ η ) ⋅ 60 ⋅ n m ⋅ 2
kc = [3.11]
2 ⋅ π ⋅ d tbm ⋅ rmc ⋅ M t ⋅ 1000 ⋅ N tbm ⋅ RPM
Ut = applied voltage of the cutterhead drive motors (V)

It = applied amperage of the thrust level (A)
nm = number of motors on the cutterhead
dtbm = TBM diameter (m)
rmc = relative radius to the position of the average cutter position, see [3.12]
Mt = applied thrust (kN/cutter)
Ntbm = number of cutters on the cutterhead
RPM = cutterhead revolutions (rev/min)
47
1.0
cosφη
0.9
0.8
0.7
0.6
0.5
0.4
0.0 0.2 0.4 0.6 0.8 1.0 1.2
It/IN
Figure 3.2 Efficiency curve of the electric motors in Table 3.3.
N tbm
∑r
i =1
i
N tbm
rmc = [3.12]
0.5 ⋅ d tbm
ri = radius to position of cutter no. i (m)
The cutter constant is calculated according to [3.13]. The resulting cutter constant of a
penetration test is shown in Figure 3.3.
kc
cc = [3.13]
i0
i0 = basic penetration of the thrust level (mm/rev)
48
0.050
cc
0.045
0.040
0.035
0.030
200 220 240 260 280 300
Mt, kN/cutter
Figure 3.3 Cutter constant of the penetration test in the Tables 3.1 and 3.2.
Ut = 660 V, nm = 4, dtbm = 3.5 m, dc = 483 mm, rmc = 0.6334, Ntbm = 25.
Figure 3.3 shows an irregular progress of the cutter constant with regard to increased
thrust level. One reason may be incorrect reading of the Ampere meters, but most
likely it is because the two lowest thrust levels have a quite low basic penetration, see
Table 3.2, making [3.13] a somewhat incorrect approximation.
49
3. PENETRATION TESTS 3.4 Specific Energy
3.4 SPECIFIC ENERGY
The gross specific energy used to break the rock may be estimated from the penetra-
tion test data or from shift log data. The specific energy estimated on that basis does
not include the cutterhead thrust system which usually has an installed power of 10 %
or less compared to the cutterhead torque system. Since the cutterhead torque is used
to estimate the specific energy for TBM boring, the muck removal through the cutter-
head is included. The contribution of the muck removal is negligible compared to the
contribution from the cutterhead rotation.
The specific energy consumption is calculated according to [3.14] and plotted as in

Figure 3.4.
U t ⋅ I t ⋅ 3 ⋅ (cos φ ⋅ η ) ⋅ n m ⋅ 3600 ⋅ 1000 ⋅ 4

Ws = (MJ/m3) [3.14]
i 0 ⋅ RPM ⋅ 60 ⋅ π ⋅ d tbm
2
⋅ 1000 2
150
MJ/m3
140
130
120
110
100
200 220 240 260 280 300
Mt, kN/cutter
Figure 3.4 Specific energy consumption based on data from the penetration test in
Tables 3.1 and 3.2.
50
4. CHIP ANALYSES 4.1 Test Procedure
4.1 TEST PROCEDURE
Analyses of the largest chips produced by a TBM may give information of the boring
process and the rock breaking mechanisms, as well as material properties of the TBM
muck and drillability parameters of the intact rock.
Chip sampling must be combined with registration of concurrent machine and per-
formance data. Chip sampling is of extra value when combined with a penetration
test. The following sampling procedure is related to penetration tests, but may be used
as a general procedure when sampling chips.
A chip sampling test should be followed by a detailed engineering geological map-

ping of the actual tunnel section.
During a penetration test, the largest chips are sampled, measured and analysed as
described below.
Sample Site
A chip sample should be collected as close to the cutterhead as possible. At an open

hard rock TBM this means at the machine conveyor or at the bridge conveyor close to
the rear end of the TBM. Caution must be exercised when the chips are picked from
the conveyor belt.
Sample Time
When the operator has stabilised the thrust level of the machine, the penetration
measurement starts. After that, one should wait at least half a minute before the chip
sampling starts, to ensure that the chips sampled are inside the penetration measure-
ment. One should stop the sampling when the penetration measurement stops.
Sample Size
A chip sample should consist of 20 large chips at each thrust level. This is achieved
by picking a larger number of chips (25 - 30), sorting the chips according to size by
51
visual judgement, and then discarding the smallest, leaving the 20 largest chips for
measurements and possible laboratory testing. The number of chips is mainly decided
by the time available for sampling at each thrust level and by the necessary number of
chips to establish a stable mean value and standard deviation of the chip sizes. Figure
4.1 shows the fluctuation in the mean value and the standard deviation of the thick-
ness of the chip sample in Table 4.1.
30
mm
25
Mean value
20
15
10
5
Standard deviation
0
0 5 10 15 20 25
Number of chips measured
Figure 4.1 Mean value and standard deviation of the chip thickness as a function of
number of chips in the sample.
Normally, the largest chips will be produced by the face cutters. Chips from the gauge
will usually not be picked since they are thinner and less wide than chips from the
face cutters. Chips produced by the centre cutters will be recognised by the evident
ring shape. Chips that by visual judgement originate from the centre or gauge should
be discarded from the sample.
Chips that seem to be broken during removal from the rock face to the sampling site
are discarded. Blocks that are fall-outs from Marked Single Joints or similar are also
discarded.
52
Muck Sample
When collecting a muck sample for sieve testing, the sample volume should be at
least 20 l and may be collected at conveyor transfer points to get the best representa-
tive sample. Muck samples collected from e.g. a truck load or a muck pile may be
subject to separation of the fines from the coarser chips, and therefore not representa-
tive samples.
53
4. CHIP ANALYSES 4.2 Chip Size
4.2 CHIP SIZE
The size of each chip is measured as largest length, width and thickness, regardless of
where along the chip the largest size occurs. It is of course important that the three
measurements are taken more or less perpendicularly to each other.
The chip size measurements are averaged for each thrust level as in the Tables 4.1 and
4.2, and plotted as a function of thrust as in Figure 4.2. The cubic chip size Vch is cal-
culated by [4.1] and plotted as in Figure 4.3. The chipping frequency fch is calculated
by [4.2] and plotted as in Figure 4.4.
Chip no. Height hch (mm) Width wch (mm) Length lch (mm)
1 24 65 267
2 43 65 209
⋅⋅⋅⋅⋅
19 16 67 193
20 26 66 204
Mean size (mm) 28.5 66.6 217.2
Standard Deviation, mm 7.9 5.8 37.2
Standard Deviation, % 27.7 8.7 15.4
Table 4.1 Chip size measurements for one thrust level of a penetration test.
dtbm = 8.5 m, dc = 432 mm. The rock type is mica gneiss.
Average Chip Size (mm) Chipping Fre-

Thrust Mt Penetration i0
quency fch
(kN/cutter) (mm/rev) hch wch lch (rev-1)
173.4 2.00 26.8 55.8 215.5 0.075
183.1 2.20 24.9 64.4 212.0 0.088
192.7 2.51 22.3 62.9 205.6 0.112
202.3 2.58 25.4 66.1 233.7 0.101
221.6 3.41 28.5 66.6 217.2 0.119
Table 4.2 Chip size measurements and chipping frequency of a penetration test.
Data of the same test as in Table 4.1.
54
300
mm Thickness
Width
250
Length
200
150
100
50
0
150 175 200 225 250
Mt, kN/cutter
Figure 4.2 Average size of the largest chips from the penetration test in Table 4.1.
500
1000 mm3
450
400
350
300
250
150 175 200 225 250
Mt, kN/cutter
Figure 4.3 Cubic chip size of the penetration test in Table 4.2.
55
Vch = l ch ⋅ wch ⋅ hch (mm3) [4.1]
lch = average length of largest chips (mm)

wch = average width of largest chips (mm)
hch = average thickness of largest chips (mm)
1
f ch = (rev −1 ) [4.2]
hch
i0
i0 = TBM penetration per revolution (mm/rev)
0.14
-1
rev
0.12
0.1
0.08
0.06
150 175 200 225 250
Mt, kN/cutter
Figure 4.4 Chipping frequency of the penetration test in Table 4.2.
56
The shape factor is a relative measure of the shape of an individual chip or of the av-
erage dimensions of 20 large chips. The calculation of the shape factor is given in
[4.3]. A plot of the shape factor of the chips from the penetration test in Table 4.2 is
shown in Figure 4.5.
f hw = hch / wch
[4.3]
f wl = wch / l ch
1
fwl
0.9
FLAT CUBIC
0.8
0.7
0.6
0.5
ELONGATED
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
ftw
Figure 4.5 Chip shape of the average chip size of the penetration test in Table 4.2.
57
4. CHIP ANALYSES 4.3 Sieve Curve
4.3 SIEVE CURVE
The sieve curve is found by sieving the TBM muck at square sieves. The sieve sizes
to find a rough particle size distribution of the TBM muck are recommended as:
• 64, 45, 32, 16, 8, 4, 2, and 1 mm.
The sieve curve established by the above sieve range should only be used for evalua-
tion of the rock breaking and boring process. To perform a standard sieve test to char-
acterise the material for technical or building purposes, the finer fractions must be
decided by sieves down to 0.063 mm and by sedimentation for the even finer frac-
tions.
Using a sieve shaker will give a good result for the fractions below 2 mm. Experience
shows that from the 4 mm sieve and upwards, some chips that should have passed will
be left at the sieve due to the flat and elongated chip shape. Hence, the sieve test must
include a manual verification of the size of each chip as illustrated in Figure 4.6.
d s
d s
Figure 4.6 Manual sieving of TBM chips. ds = square sieve size.
A chart for presentation of the sieve test results is shown in Appendix D. Normalised
sieve curves are found in the Project Report 1F-98 HARD ROCK TUNNEL
BORING The Boring Process.
58
4. CHIP ANALYSES 4.4 Kerf Depth Factor
4.4 KERF DEPTH FACTOR
The kerf depth factor is measured where the chip has its largest thickness. In the labo-
ratory, the chips are cut by diamond saw, which gives the best measurements. In the
field one has to rely more on judgement as the measurements are taken on uncut
chips.
Concerning the accuracy of the measurements, one should bear in mind that the kerf
depth factor is used to show a trend, not for precise calculations. Furthermore, when
the number of chips increases, the influence of the random measurement error is de-
creased.
The kerf depth is measured as shown in Figure 4.7. The kerf depth factor is:
ik
f kd = [4.4]
hch
fkd = kerf depth factor

ik = kerf depth at chip forming (mm)
hch = maximum chip thickness (mm)
C u tte r e d g e
ik in d e n ta tio n
h c h
Figure 4.7 Measurement of the kerf depth at chip forming.
59
4. CHIP ANALYSES 4.4 Kerf Depth Factor
It may be difficult or uncertain to identify the exact kerf depth or the cutter ring
indentation of each chip. The best indicator is the fine powder that may be found at
the side of the chip, combined with the form of the chip side towards the kerf, see
Figure 4.8. Deficient identification of the kerf depth should lead to discarding the chip
from the kerf depth measurements.
60
4. CHIP ANALYSES 4.5 Crack Growth
4.5 CRACK GROWTH
The best approach to study the crack growth and the chipping mechanisms for hard
rock tunnel boring is to examine cross sections of the large chips. When the chips are
cut by diamond saw, the cracks inside the chip are easy to identify. The chip forming
cracks are of course found as the surface of the chip.
Usually, the chip is cut where its thickness is largest. It is supposed that the final
forming of the chip occurred at that part of the chip. A three-dimensional model of the
crack pattern may be established by cutting the chip in equally spaced slices.
The orientation of the chip with regard to which side has been towards the cutterhead
is decided by the chip form and by the fine powder remaining in the kerfs made by the
cutter along the chip. Figure 4.8 shows a cross section of a chip with easily identifi-
able cutter tracks (kerfs) and radial cracks from cutter passes prior to the chip form-
ing.
C ra c k s fro m p r e v io u s p a s s e s
ik
ik
h c h h c h
Figure 4.8 Identification of cutter tracks and radial cracks in a chip.
Crack growth is best observed in isotropic and fine-grained rock types.
61
4. CHIP ANALYSES 4.6 Rock Properties
4.6 ROCK PROPERTIES
The largest chips may be used for testing of drillability, strength and wear properties.
Actual tests to be performed on chips are DRI, Mini-DRI, CLI, CAI and Point Load
Strength. One must however observe that the chips have been subject to high stress
that may have influenced the rock properties somewhat.
DRI
The Brittleness Value S20 of the DRI test is believed to be influenced by the type of
test material. TBM chips will most likely contain some small cracks from the boring
process. Parallel tests of 50 mm diameter cores and TBM chips indicate that the
Brittleness Value (and therefore the DRI value) tested on chips is 2 - 4 units higher
than the Brittleness Value tested on 50 mm cores. The few available data covers the
Brittleness Value range of 35 - 50. Since the systematic error in the DRI value tested
on chips seems to be relatively small, it is advisable to use TBM chips as test material
in the DRI test.
The chips must be of a size and orientation so that one is able to perform the Sievers'
J-value (SJ) test parallel to the possible foliation of the rock. This is achieved in most
cases by cutting the chips in the desired orientation. The SJ test may be influenced by
microcracks resulting from the cutter forces.
Mini-DRI
The brittleness test of the Mini-DRI uses the crushed aggregate fraction of 2 - 4 mm.
The Mini-DRI value is believed to be little influenced by the type of test material as
long as it is chips, cores or blocks. Hence, the largest TBM chips are well suited to be
used in the Mini-DRI test. The SJ test requires the same size and orientation of the
chips as the standard DRI test.
CLI
The abrasion tests AV and AVS use the crushed fraction of grain size < 1 mm. The AV
and AVS value are not believed to be influenced by the type of test material as long as
it is crushed from larger pieces, and the largest TBM chips are well suited for these
tests. In order to calculate the CLI, the chips must be of a size and orientation so that
one is able to perform the SJ test parallel to the possible foliation of the rock.
62
4. CHIP ANALYSES 4.6 Rock Properties
CAI
The CAI test is a scratch test performed on a rough rock surface. The TBM chips are
well suited as test material to test the CAI value.
Point Load Strength

The largest chips may be suited for point load testing, providing that the chips se-
lected are oriented parallel or perpendicular to the rock structure. The point load test
may be carried out in the field by portable equipment, giving an immediate measure
of the rock strength. A correlation between the point load index Is and the DRI is
found in the Project Report 1E-98 HARD ROCK TUNNEL BORING Geology
and Site Investigations.
The Point Load test may be influenced by microcracks resulting from the rock cutting
process.
63
5. BACK-MAPPING 5.0 Introduction
5.0 INTRODUCTION
The engineering geological back-mapping of a bored tunnel should consist of the fol-
lowing:
• Continuous and detailed mapping of rock mass fracturing

• Continuous and detailed mapping of rock type distribution
• Rock sampling and laboratory testing of rock properties.
The engineering geological back-mapping establishes a geological model of the tun-

nel, to be used for evaluation of the machine performance, cutter life, machine utilisa-
tion, etc.
It is convenient to map longer sections, e.g. 500 m, for each mapping round. Back-
mapping in tunnels lined with concrete elements or shotcrete at the cutterhead is very
difficult to perform with the purpose to establish a continuous geological model. In
such tunnels the back-mapping must be improvised and done at points whenever the
rock surface is available.
The mapping is a subjective task with regard to degree of fracturing, type of fractures,
rock type, etc. The quality of the mapping will improve substantially when a team of
two persons is doing the back-mapping.
The parameters used in the back-mapping are the same as those used in the site inves-
tigations, as described in the Project Report 1E-98 HARD ROCK TUNNEL
BORING Geology and Site Investigations.
64
5. BACK-MAPPING 5.1 Mapping Procedures
5.1 MAPPING PROCEDURES
The mapping in the tunnel should be recorded on a sheet with standardised entries.
An example of a completed sheet for a 50 m tunnel section is shown in Figure 5.1. A
blank form is found in Appendix D, and is also available in digital format1.
S ig n a tu r e :
T U N N E L : M E R K R A F T D a te : 3 / 2 - 9 2
A B / B S
C h a in -
a g e 4 5 5 0 6 0 7 0 8 0 9 0 4 6 0 0
1 3 5 °
L e ft w a ll
9 0 °
4 5 °
1
R o o f
0 °
1
-4 5 °
R ig h t w a ll
-9 0 °
-1 3 5 °
12 g / 3 9 °
R o c k ty p e
G r e e n s c h is t
(G r e e n s t o n e )
F r a c tu r in g
S t III ÷ S t II - III S t II + S t III S t III
1 1
C o m m e n ts
D r ip p in g f o l: 2 1 1 g / 4 2 ° a @ 3 6 ° C la y f ille d 1 - 2 c m
tu n n e l ~ 2 8 0 g
Figure 5.1 Completed back-mapping sheet from a 3.5 m diameter tunnel.
1
Contact the author.
65
+ + + + + +
chain- left roof right left roof right
age wall wall wall wall
0° 0°
45° roof -45° roof

60° -60°
90° left right -90° 90° -90°

wall wall left right
wall wall
135° -135°
180° 180°
-180° -180°
dtbm < 5 - 8m dtbm > 5 - 8m
Figure 5.2 Representation of the tunnel circumference in the mapping sheet. Right
and left wall applies when looking towards the tunnel face.
The mapping is concentrated on 10 m sections. Each section is mapped according to

the following steps:
• Record the Marked Single Joints and measure strike and dip where convenient.
• Record other singular phenomena like intrusions, water, rock fall-outs, rock sup-
port, etc.
• Decide the rock type.
• Decide the number of fracturing systems (usually one or two).
• Decide the type of fracturing for each system (St or Sp).
• Decide the degree of fracturing for each system.
• Measure strike (αs) and dip (αf) of the fracturing system(s) at least once for each
50 m.
• Measure the strike of the tunnel (αt) at the same time as the strike and dip of the
fracturing is measured.
The registrations should be an average for the 10 m section. If necessary (e.g. change
of rock type), the 10 m section may be subdivided.
66
The degree of fracturing should consequently be evaluated along a scanline at one of

the tunnel walls, preferably in the lower part of the wall since that gives a good possi-
bility to take a closer look at the rock mass. In special cases when the scanline along
the wall is obviously not representative for the tunnel section (e.g. for intrusions) one
may evaluate the section volume as a whole.
In most cases, the degree of fracturing is recorded by visual interpretation with occa-
sional measurements of the distance between the planes of weakness. The distance is
measured perpendicular to the planes of weakness as shown in Figure 5.3.
= fis s u r e s
-4 5 °
R ig h t 2 4 4 0 2 4 3 5
tu n n e l
w a ll
S c a n lin e
0 6 7 5 0 0 0
fo r m a p p in g 1 3 5 1 2 5 9 0 0 1 0
-1 3 5 °
(1 3 5 0 + 6 7 5 + 1 2 5 0 + 9 0 0 + 1 0 0 0 )m m
a = = 1 0 3 5 m m » S t I-
f 5
Figure 5.3 Measurement of fracture spacing. The fissures have strike approximately
perpendicular to the tunnel axis.
Figure 5.4 shows two examples where it may be difficult to evaluate the degree of
fracturing. Case 1 has various possibilities, of which 3 are evaluated below.
• The rock mass is massive (homogeneous) outside the tunnel. Hence, there are only
3 fissures to consider, and the average distance between the fractures may be esti-
mated as:
(500 + 600) mm
af = = 550 mm
2
67
This is obviously ambiguous, and other possibilities must be considered.
• The "next" fissures are just outside the tunnel in the roof and the invert. Average
distance between the fractures will be:
(800 + 500 + 600 + 1600) mm

af = = 875 mm
4
875 mm corresponds approximately Fissure Class I- (St I-).
• The "next" fissures are 800 mm outside the tunnel roof and 1600 mm outside the
tunnel invert. Average distance between the fractures will be:
(800 + 800 + 500 + 600 + 1600 + 1600) mm

af = = 1475 mm
4
1475 mm corresponds approximately Fissure Class 0-I (St 0-I).
The conclusion for Case 1 is that the degree of fracturing may be classified as St I-
or lower, with St 0-I as the recommended classification.
Case 2 also has various possibilities, of which 2 are evaluated below.
• The rock mass is massive (homogeneous) outside the tunnel. Hence, there are 6
fissures to consider, and the average distance between the fractures may be esti-
mated as:
500 mm
af = = 100 mm
5
This is obviously ambiguous, and other possibilities must be considered.
68
• If the "concentration" of fissures or joints has some extent along the tunnel (e.g.
more than 2 ⋅ dtbm), it may be regarded as a weakness zone and classified as a
prominent Marked Single Joint.
The conclusion for Case 2 is that the concentrated fissures or joints may be classi-
fied as a Marked Single Joint. It is however difficult to give general rules for simi-
lar cases for when to classify as Marked Single Joints and when to classify as sys-
tematic fractured rock mass.
e s
s u r
m m F is
8 0 0
m m m
0 m
5 0 0 2 2 0
m m
6 0 0
m m m
0 m 5 0 0
1 6 0
m m
8 0 0
re s
s s u
6 fi
C a s e 1 C a s e 2
Figure 5.4 Examples of evaluation of the degree of fracturing in a 3.5 m diameter

tunnel. The fissures have strike approximately perpendicular to the tun-
nel axis and the dip is close to horizontal.
The best way to adjust and fine tune the classification of the degree of fracturing as
seen in the tunnel wall, is to observe the tunnel face during a standstill of the TBM
and experience how the fracturing is utilised in the rock breaking process.
The notation and registrations of the back-mapping may be individual, but some basic
rules should be applied:
• The preferred sectioning of the tunnel circumference is as follows: The roof and
the walls of the mapping form cover a sector of 90° each, leaving a sector of 90°
in the invert. When necessary, the chainage field and the field below the right wall
field are utilised to record Marked Single Joints etc., see Figure 5.1.
69
• For large diameter tunnels, the roof and wall sectors of the mapping form may be
increased to 120° to be able to cover the complete tunnel (see Figure 5.2 and Ap-
pendix D).
• Marked Single Joints are recorded as continuous lines, other rock mass fracturing
is recorded as dotted lines.
• The type and degree of fracturing must be noted for each 10 m section. Do not use
arrows or similar to indicate "continues from, or the same as, the previous sec-
tion".
• Strike and dip is measured in a 400g or 360° scale, with the dip direction always to
the same side of the strike direction2.
Quality Control
The engineering geological back-mapping is a highly subjective process, with a

strong element of judgment in the classification of the degree of fracturing. To ensure
a good quality of the classification, the following procedures are recommended:
• A team of two persons should perform the back-mapping.

• Evaluate each 10 m section individually, and use enough time when mapping.
• Before the mapping of a new tunnel section starts, check and evaluate the map-
ping of the last 30 - 50 m of the previous section. This will adapt the mapping per-
sonnel to the site geology before mapping of the actual section starts and uncover
possible disagreement in the classification of the previous section.
• When the mapping of a tunnel section is finished, re-map selected subsections of
20 - 30 m length at 150 - 200 m intervals. Using only 10 m subsections when re-
mapping will not give the desired quality control.
• When the mapping is finished, check the mapping of selected subsections against
the machine performance to confirm that the variation in the machine performance
corresponds to the variation in the degree of fracturing.
2
See Section 2.1 in the Project Report 1D-98 HARD ROCK TUNNEL BORING Geology and Site
Investigations.
70
5. BACK-MAPPING 5.2 Aggregation of Mapping Data
5.2 AGGREGATION OF MAPPING DATA
The data from the back-mapping must be aggregated to be used further. The geologi-
cal model of the tunnel is typically divided into sections, in which as many as possible
of the boring parameters are constant or showing little variation.
The most important parameters to consider when the tunnel is divided into sections,
are:
• Rock type and rock properties such as DRI, CLI, quartz content
• General level of rock mass degree of fracturing
• General angle between the tunnel axis and the planes of weakness
• Tunnel direction
• Machine parameters such as thrust level, cutterhead RPM, cutter type, etc.
The aggregation of geological data is basically an averaging of rock properties and

rock mass degree of fracturing.
Rock Properties
If test results for more than one rock sample is available for one geological tunnel
section, the arithmetic mean of the laboratory test results or indices are used.
In special cases, one may use a weighted average (parameters weighted by tunnel
length). When rock samples are assumed to represent a given length of a tunnel sec-
tion, it is recommended to subdivide the tunnel section rather than to use a weighted
average for the original section.
Rock Mass Fracturing
The systematic rock mass fracturing of the tunnel section is grouped according to the
degree of fracturing as shown in Figure 5.6.
The angle between the tunnel axis and the planes of weakness is estimated from pole
plots of the strike and dip measurements (see Project Report 1D-98 HARD ROCK
71
TUNNEL BORING Geology and Site Investigations), or calculated as the average

of direct measurements or estimates of α taken in the section.
The average ks factor of the section is calculated according to [5.1] and Table 5.1.
IV
4 .0
F is s u r e C la s s J o in t C la s s
k s
3 .0
III-IV
2 .0
III II
II-III I-II
1 .0
II I
I 0 -I
0 0
1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0
a , d e g re e s
Figure 5.5 Fracturing factor. From the Project Report 1B-98 HARD ROCK
TUNNEL BORING Advance Rate and Cutter Wear. The equations of
the ks factor are available from the author.
The ks factor of fracturing classes not shown as curves in Figure 5.5 is found by linear
interpolation between the given curves.
72
90
m
80
70
60
50
40
30
20
10
0
st I+ st I-II st II- st II st II+ st II-III
Degree of fracturing
Figure 5.6 Example of distribution of rock mass fracturing of a 235 m long tunnel
section.
∑l i
k s − avg = n
i =1
[5.1]
li
∑
i =1 k s −i
li = tunnel length of fracturing class i of the section

ks-i = ks factor of fracturing class i of the section.
The ks-avg relates to the basic net penetration rate I0 of the tunnel section, see below.
73
li li
i Fracturing Class
Tunnel Length of Frac-
ks-i
k s −i
∑l i ∑k
turing Class i (m) s −i
1 St I+ 20 0.87 22.99 20 22.99

2 St I-II 50 0.96 52.08 70 75.07
3 St II- 80 1.06 75.47 150 150.54
4 St II 54 1.15 46.96 204 197.50
5 St II+ 20 1.26 15.87 224 213.37
6 St II-III 10 1.37 7.30 234 220.67
6
∑l i
234
k s −avg = 6
i =1
= = 1.06 [5.1]
li 220.67
∑
i =1 k s − i
For α = 25°, ks-avg =1.06 means a Fissure Class of approximately St II-.
Table 5.1 Calculation of ks-avg.
The total tunnel length of the section influenced by Marked Single Joints is found by
summing the length in the tunnel of each MSJ. Table 5.2 shows how the 8 Marked
Single Joints in Figure 5.1 are treated.
According to Figure 5.7, the Marked Single Joints should be grouped in two groups:
• MSJs giving a correction factor kesp < 1.4

• MSJs giving a correction factor kesp = 1.4 (the recommended maximum value)
This may roughly be achieved by grouping the Marked Single Joints in two catego-
ries:
• MSJs each influencing a tunnel length less than the tunnel diameter, i.e. αesp > 45°
• MSJs each influencing a tunnel length greater than the tunnel diameter,
i.e. αesp ≤ 45°
The average angle αesp between the tunnel axis and each MSJ group is found by [5.2].
The basic net penetration rate I0 of the tunnel section is found by [5.3].
74
nesp ⋅ d tbm
α esp = arctan (°) [5.2]
l esp
nesp = number of MSJs in the MSJ group of the section

lesp = cumulated length of MSJs in an MSJ group of the section (m)
dtbm = TBM diameter (m)
In l esp −i
I0 = (l j − ∑ l esp −i + ∑ ) (m/h) [5.3]
lj k esp −i
In = net penetration rate of the tunnel section (m/h)

lj = tunnel length of the section (m)
lesp-i = cumulated tunnel length of MSJ group i of the section (m)
kesp-i = correction factor MSJ group i of the section, see Figure 5.6.
DRI=30 DRI=40
1.4
kesp DRI=50
1.3
DRI=60
1.2
1.1
10 20 30 40 50 60
a esp , degrees
Figure 5.7 Correction factor for Marked Single Joints. From the Project Report 1B-
98 HARD ROCK TUNNEL BORING Advance Rate and Cutter Wear.
75
Depending on the practice used in the back-mapping, it may be necessary to correct

the recorded length of Marked Single Joints. When the invert sector of the tunnel is
not included in the mapping form (see Figure 5.2), non-vertical joints will not be re-
corded with their real length in the form. Joints with strike perpendicular to the tunnel
axis will have the largest deviation, and the recorded length of these is 75 % of the
real influence length. For other strike and dip angles, the correction is estimated
roughly.
When the mapping form does not include the invert sector, it is a good possibility to
use the chainage field and the field below the right wall field to represent half of the
invert sector each, as indicated in Figure 5.2. This is utilised for Marked Single Joint
no. 2 in Figure 5.1.
Recorded Real Length in Tunnel Cumulated Length in Tunnel

MSJ No. Length in (m) (m)
Tunnel (m) MSJ Group 1 MSJ Group 2 MSJ Group 1 MSJ Group 2
1 8 8 8
2 1.5 2 2
3 4 5 13
4 4.5 4.5 17.5
5 3.5 3.5 5.5
6 2 2 7.5
7 4.5 6 23.5
8 4 5.5 29
n esp −1 ⋅ d tbm 3 ⋅ 3.5
α esp −1 = arctan = arctan = 54.5° ⇒ kesp-1 = 1.4
l esp −1 7 .5
n esp −2 ⋅ d tbm 5 ⋅ 3 .5
α esp −2 = arctan = arctan = 31° ⇒ kesp-2 = 1.29
l esp − 2 29
Table 5.2 Calculation of lesp and αesp for a 3.5 m diameter tunnel. Data from Fig-
ure 5.1. Real Length in Tunnel is roughly estimated. DRI = 40.
76
5. BACK-MAPPING 5.3 Rock Sampling
5.3 ROCK SAMPLING
The most important quality of a rock sample for laboratory testing, is that it is repre-
sentative of the rock type. The selection of sample sites must therefore be carefully
evaluated.
The following procedures may be utilised to find the best sample sites:
• Suitable sample sites with regard to representative and constant rock conditions as
well as sampling possibilities (block or core sample) are recorded during the back-
mapping.
• The number of samples is decided from the back-mapping and the machine per-
formance data. Each rock type should be represented by at least one sample. One
should at least test one rock sample for each 500 m of tunnel.
• The sample site should be located in a 20 - 30 m long subsection of stable degree
of fracturing and machine performance.
• The sample site should be located where the Ic/In ratio is close to 1.0, see Table
2.3.
• The sample site should not be close to larger discontinuities or intrusions, where
the rock properties may be influenced by alteration.
• Avoid sample sites with a high stress concentration along the tunnel circumfer-
ence.
The sampling method may vary, but block or core samples are recommended. Cores
should have a diameter of 50 mm or more. One sample may consist of several pieces
totalling 10 kg. Each piece should have a weight of at least 0.5 kg. Samples consisting
of the largest chips from the boring may be used for laboratory testing, with the re-
strictions given in Section 4.6.
It is a good practise to collect one or two large chips routinely (e.g. each day) to re-
cord the rock type, grain size, colour, etc. Typical chips from each 50 m tunnel sec-
tion, each week or similar lengths or time periods are stored until the tunnel is fin-
ished, building a rock database for the tunnel.
77
5. BACK-MAPPING 5.4 Achieved vs. Predicted Performance
5.4 ACHIEVED VS. PREDICTED PERFORMANCE
When the DRI, CLI, quartz content, ks-avg, kesp and the applied machine parameters
have been found for a tunnel section, the achieved penetration rate, advance rate and
cutter consumption may be compared to the prediction model in the Project Report
1B-98 HARD ROCK TUNNEL BORING Advance Rate and Cutter Wear. Thus,
the actual tunnelling performance may be evaluated against a standardised model.
New data as a basis for improvement of the prediction models will also be provided in
such cases.
The model for penetration addition due to Marked Single Joints is based on less data
than the penetration rate model for systematic fractured rock mass. Hence, when
evaluating the machine performance as net penetration rate, one will get the best pic-
ture when using data from tunnel sections with few or no Marked Single Joints.
The data from the back-mapping should also be compared to the predicted geological
model established through the site investigations. Such verification will bring valu-
able information to improve:
• The site investigation routines

• The interpretations of surface mapping and core hole logging
• The contract specifications and how to handle changed rock conditions.
78
APPENDIX A. Previous Editions
A. PREVIOUS EDITIONS
Previous editions of the Hard Rock Tunnel Boring Report including project group
members:
1-76 Norwegian edition

Bengt Drageset
Roy-Egil Hovde
Erik Dahl Johansen
Roar Sandnes
O. Torgeir Blindheim
Odd Johannessen
1-79 Norwegian edition

Knut Gakkestad
Jan Helgebostad
Svein Paulsen
Oddbjørn Aasen
Erik Dahl Johansen
O. Torgeir Blindheim
Odd Johannessen
1-83 Norwegian and English edition

Arne Lislerud
Steinar Johannessen
Amund Bruland
Tore Movinkel
Odd Johannessen

Arne Lislerud
Amund Bruland
Bjørn-Erik Johannessen
Tore Movinkel
Karsten Myrvold
Odd Johannessen

Bård Sandberg
Amund Bruland
Jan Lima
Odd Johannessen
79
APPENDIX B. Research Partners
B. RESEARCH PARTNERS
The following external research partners have supported the project:
• Statkraft anlegg as
• Norwegian Public Roads Administration
• Statsbygg
• Scandinavian Rock Group AS
• NCC Eeg-Henriksen Anlegg AS
• Veidekke ASA
• Andersen Mek. Verksted AS
• DYNO Nobel
• Atlas Copco Rock Drills AB
• Tamrock OY
• The Research Council of Norway
80
APPENDIX C. List of Parameters
C. List of Parameters
The parameters used in the report are listed in the following. The list is according to
when the parameter first is explained or treated.
Parameter Description Unit Page
af Average spacing between planes of weakness cm 67

AV Abrasion Value (tungsten carbide) mg/5 min 62
(see also PR 13A-98)
AVS Abrasion Value Steel (cutter ring steel) mg/1 min 62
b Penetration coefficient 44
cc Cutter constant - cutterhead torque 48
CAI CERCHAR Abrasivity Index 63
CLI Cutter Life Index 62
dc Cutter diameter mm 25
ds Sieve opening mm 58
dtbm TBM or cutterhead diameter m 47
dtc Effective diameter of a thrust cylinder mm 44
DRI Drilling Rate Index 62
fch Chipping frequency 56
fD Cutterhead factor - cutter wear 25
fD0 Cutterhead factor of the reference cutterhead (1.133) 25
fhw Chip shape factor - thickness to width 57
fkd Kerf depth factor in chip forming 59
fwl Chip shape factor - width to length 57
hc,i Machine hours of cutter change no. i h 32
hch Individual and average largest chip thickness mm 54
Hf Cutter ring life - for the cutterhead sm3/c 31
Hh Cutter ring life - for the cutterhead h/c 28
hi Measured intermediate ring height of an
individual cutter ring at the cutterhead mm 34
Hm Cutter ring life - for the cutterhead m/c 28
Hni Number of cutter rings used at cutter position no. i 25
81
hr Measured ring height of replaced cutter ring mm 34

Hri Relative cutter ring life of cutter position no. i 25
hwi Intermediate wear height of an
individual cutter ring at the cutterhead mm 35
hwr Wear height of replaced cutter ring mm 35
h0 Measured ring height of new cutter ring mm 34
HRC Rockwell C hardness number 36
IB Applied amperage A 14
IBj Amperage over subsection j A 14
IBm Average amperage over a given tunnel length A 14
Ic Net penetration rate
- calculated from the cutter consumption m/h 32
ik Kerf depth at chip forming mm 59
Im Average net penetration rate m/h 10
In Net penetration rate m/h 9
IN Rated amperage of a cutterhead drive motor A 47
Inj Net penetration rate of subsection j m/h 10
Is Point load strength index MPa 63
it Measured penetration of one level
in a penetration test mm 41
It Applied amperage of a penetration test level A 42
Iu Weekly advance rate m/week 17
Iun Normalised weekly advance rate m/week 21
i0 Basic penetration mm/rev 44
I0 Basic net penetration rate m/h 75
kc Cutter coefficient - cutterhead torque 48
kD Correction factor for TBM diameter
- cutter ring life 25
kesp Correction factor for Marked Single Joints 74
ks Fracturing factor 72
ks-avg Average fracturing factor 73
ks-i Fracturing factor of Fracturing Class i of a section 73
lc,i Chainage of cutter change no. i mm m 32
lch Individual and average largest chip length mm 54
lesp Cumulated length of MSJs in an
MSJ group of a section m 75
82
li Tunnel length of Fracturing Class i of a section m 73

lj Tunnel length of subsection j m 10
Lt Total tunnel length km 11
l1 Chainage at the start of a time period
or tunnel section m 20
l2 Chainage at the end of a time period
or tunnel section m 20
MB Gross average thrust kN/cutter 12
MBm Gross average thrust over a given tunnel length kN/cutter 12
MBj Gross average thrust over subsection j kN/cutter 12
Mt Gross average thrust of a penetration test level kN/cutter 40
M1 Critical thrust to achieve a penetration
rate of 1 mm/rev kN/cutter 44
MSJ Abbreviation of Marked Single Joint 74
Nc Cutter change no. 28
nesp Number of MSJs in the MSJ group of a section 75
Ni Cutter position no. i 25
nm Number of cutterhead drive motors 14
Ntbm Number of cutters on the cutterhead 25
ntc Number of thrust cylinders of the TBM 44
nu Number of productive weeks of a period week 20
pB Applied thrust cylinder pressure bar or psi 41
pt Thrust cylinder pressure of
a penetration test level bar or psi 41
ri Radius to cutter position no. i m 48
rmc Relative radius to the position
of the average cutter position 48
rri Relative radius of cutter position no. i 25
RPM Cutterhead revolutions per minute rev/min 14
S20 Brittleness Value after 20 impacts % 62
SJ Sievers' J-value by miniature drill mm/10 62
Tb Net time for boring h 16
TB Applied torque kNm 14
83
Tbak Time used for repair and service of

the backup equipment h 15
Tbj Machine hours used to bore subsection j h 10
Tbr Time used for boring and regripping h 15
Tc Time used for cutter change and inspection h 15
Teh Effective working hours h/week 17
(see also PR1B-98)
Tex Available time for tunnel excavation
- excluding rock support work h 17
Tmt Stop time due to rock transport problems h 15
Toa Stop time due to other activities h 15
Tot Stop time due to other transport problems h 15
Tp Stop time related to the tunnelling crew, such as
travel, change of crews, lunch breaks, etc. h 15
Tr Time for regripping h 16
Trs Stop time due to rock support, water inflows
and other geological causes h 15
Ts Stop time due to surveying h 15
Tsh Total shift hours - working hours h 16
tt Duration of one thrust level of a penetration test min 41
Ttbm Time used for repair and service of the TBM h 15
Tw Stop time due to water, electricity or ventilation problems h 15
t1 Machine hours at the start of a time period
or tunnel section h 16
t2 Machine hours at the end of a time period
or tunnel section h 16
ua Achieved machine utilisation % 17
UB Applied voltage of the cutterhead drive motors V 14
um Averaged machine utilisation % 18
UN Rated voltage of the cutterhead drive motors V 42
un Normalised machine utilisation
- per week of 100 shift hours % 17
Ut Applied voltage of the cutterhead drive motors
during a penetration test V 42
Vch Cubic chip size mm3 56
wch Individual and average largest chip width mm 54
84
wh Cutter wear rate - for the cutterhead c/h 28

wj,i Instantaneous cutter wear rate of cutter position
no. i from Nc = j to Nc = j+1 c/h 28
wj,i Instantaneous cutter wear rate of cutter position
no. i from Nc = j to Nc = j+1 c/m 28
wm Cutter wear rate - for the cutterhead c/m 28
Ws Specific energy of rock cutting with TBM MJ/m3 50
cosφ⋅η Efficiency factor of the cutterhead motors 14
α Angle between the tunnel axis and
the planes of weakness ° 72
αesp Angle between the tunnel axis and
Marked Single Joints ° 74
αf Dip angle of a fracture or fracturing system g
or ° 66
αs Strike angle of a fracture or fracturing system g
or ° 66
αt Strike angle of the tunnel axis g
or ° 66
85
APPENDIX D1. Mapping Sheet ±135°
D1. MAPPING SHEET ±135°°
-1 3 5 °
1 3 5 °
-4 5 °
-9 0 °
9 0 °
4 5 °
0 °
S ig n a tu r e :
D a te :
T U N N E L :
C h a in -
L e ft w a ll R o o f R ig h t w a ll R o c k ty p e F r a c tu r in g C o m m e n ts
a g e
The sheet is also available in various digital formats.
86
APPENDIX D2. Mapping Sheet ±180°
D2. MAPPING SHEET ±180°°
-1 8 0 °
1 8 0 °
-6 0 °
-9 0 °
9 0 °
6 0 °
0 °
S ig n a tu r e :
D a te :
T U N N E L :
C h a in -
L e ft w a ll R o o f R ig h t w a ll R o c k ty p e F r a c tu r in g C o m m e n ts
a g e
87
S H IF T L O G T B M P R O J E C T :
L a s e r ta rg e ts : S ta r t o f s h ift E n d o f s h ift
D3. SHIFT LOG
APPENDIX
D a te : O p e ra to r: F ro n t B a c k F ro n t B a c k
6 6 6 6
4 4 4 4
M a c h in e h o u r s s to p : C h a in a g e s to p : 2 2 2 2
0 0 0 0
M a c h in e h o u r s s ta r t: C h a in a g e s ta r t: 2 2 2 2
4 4 4 4
B o r in g tim e : B o r e d le n g th : 6 6 6 6
6 4 2 0 2 4 6 8 6 4 2 0 2 4 6 8 6 4 2 0 2 4 6 8 6 4 2 0 2 4 6 8
D a y : 0 7 0 8 0 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9
N ig h t: 1 9 2 0 2 1 2 2 2 3 2 4 0 1 0 2 0 3 0 4 0 5 0 6 0 7
A m p e re
T h ru s t

B o r in g in c l. r e g r ip
C u tte r c h a n g e
a n d in s p e c tio n
W a te r , e le c tr ic ity ,
v e n tila tio n
T B M , r e p a ir a n d
s e r v ic e
B a c k - u p , r e p a ir a n d
s e r v ic e
C o n tin u o u s c o n v e y o r ,
r e p a ir a n d s e r v ic e
A u x ilia r y tr a n s p o r t
R o c k s u p p o rt
W a te r in flo w
S u r v e y in g
L u n c h b re a k
O th e r
C o m m e n ts :
88
D3. Shift Log
R E A S O N F O R C H A N G E : W = (A b r a s iv e ) w e a r
APPENDIX
C = R in g c h ip p in g
B = B lo c k e d b e a r in g s
L = O il le a k a g e
F = B ro k e n b o lts
2 4
2 2 O = O th e r ( w ith r e m a rk )
25 P o s . C u tte r n o . R e a s o n P o s . C u tte r n o . R e a s o n
2 4 2 2
n o . in o u t n o . in o u t
1 4
D4. CUTTER CHANGE LOG
1 4 1 1 2 5
1 1
1 2 1 -3 1 5
12
1 -3 1 6
1 9
1 9
7 5 1 7
1 6
6 .
1 6
6 . 6 1 8
9 .
7 1 9
2 3
8
3 1 2 4
1 8
9 .
8 2 0
8
2 3
1 8
9 2 1

1 0 2 2
1 3
5
1 3
1 0
1 1 2 3
1 7
5
1 7
1 0 1 2 2 4
1 5
1 3 2 5
2 0
2 1
1 5 1 4
2 1 2 0
C o m m e n ts :
C u tte r c h a n g e n o .
D a te
C h a in a g e
M a c h in e h o u r s
T o ta l n o . o f c u tte rs S H IF T : O P E R A T O R :
89
D4. Cutter Change Log
P a s s in g C L A Y S IL T S A N D G R A V E L
%
1 0 0
APPENDIX
9 0
8 0
D5. SIEVE CURVE SHEET
7 0
6 0
5 0
4 0

3 0
2 0
1 0
0
S ie v s iz e , m m 0 .0 6 3 0 .1 2 5 0 .2 5 0 .5 1 2 4 8 1 6 3 2 4 5 6 4
0 .0 0 0 6 0 .0 0 1 0 .0 0 2 0 .0 0 5 0 .0 1 0 .0 2 0 .0 6 0 .1 0 .2 0 .5 1 2 5 1 0 2 0 6 0
m m
1 0 0
90
D5. Sieve Curve Sheet
APPENDIX E. Penetration Test Spreadsheet
E. PENETRATION TEST SPREADSHEET
A B C D E
Normalised
1 Mt i0 log10(Mt) log10(i0) Penetration
Curve
2 205.5 1.74 2.312811826 0.240549248 1.742153183
3 231.2 2.41 2.36398783 0.382017043 2.418340339
4 256.9 3.28 2.409764104 0.515873844 3.242800145
5 282.6 4.2 2.451172158 0.62324929 4.228296974
6 #NUM! #NUM! 0
7 #NUM! #NUM! 0
8
9 ARX + BR 2.783161475 -6.195842434
10
11 6.37027E-07
12
13 M1= 168.3405072
12
15 b= 2.783161475
Cell Entries
A2:A7 Applied thrust of two to six test levels

B2:B7 Achieved basic penetration of two to six test levels
C2:C7 Log values of the cutter thrust [=LOG10(A2)….=LOG10(A7)]
D2:D7 Log values of the basic penetration [=LOG10(B2)….=LOG10(B7)]
B9 Text as shown
C9:D9 {=LINEST(D2:D7,C2:C7,TRUE,FALSE)}
Enter the formula as an array formula into both cells by:
1 Select the range C9:D9
2 Type the following formula:
=LINEST(D2:D7,C2:C7,TRUE,FALSE)
3 Press Ctrl+Shift+Enter
The formula will be displayed surrounded by brackets as shown above.
D11 =10^D9
C13 Text as shown
D13 =(1/D11)^(1/C9)
C15 Text as shown
D15 =C9
F2:F7 =(A2/D$13)^D$15…..=(A7/D$13)^D$15
91
ISBN 82-471-0281-1
ISSN 0802-3271
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Hard Rock Tunnel Boring Vol. 6 - Performance Data and Back-mapping

Thesis · November 2000

Hard Rock Tunnel Boring View project

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0.1 Project Reports about Hard Rock Tunnel Boring 3

0.2 Field Performance Studies 6

1.1 Net Penetration Rate 9

1.2 Gross Thrust 12

1.4 Machine Utilisation 15

1.5 Weekly Advance Rate 20

1.6 Parameter Summary 22

2.1 Consumption per Position 24

2.2 Instantaneous Consumption 28

2.3 Ring Wear 34

3.1 Test Procedure 40

3.2 Penetration Curve 44

3.3 Cutter Coefficient 47

3.4 Specific Energy 50

4.1 Test Procedure 51

4.2 Chip Size 54

4.3 Sieve Curve 58

4.4 Kerf Depth Factor 59

4.5 Crack Growth 61

4.6 Rock Properties 62

5.1 Mapping Procedures 65

5.2 Aggregation of Mapping Data 71

5.3 Rock Sampling 77

5.4 Achieved vs. Predicted Performance 78

D.1 Mapping Sheet ±135° 86

D.2 Mapping Sheet ±180° 87

D.3 Shift Log 88

D.4 Cutter Change Log 89

D.5 Sieve Curve Sheet 90

E. Penetration Test Spreadsheet 91

HARD ROCK TUNNEL BORING Performance Data and Back-mapping

• 1A-98 HARD ROCK TUNNEL BORING Design and Construction

In addition, HARD ROCK TUNNEL BORING Background and Discussion gives

For reference, registration and similar, we ask for the following:

NTNU-Anleggsdrift (1998): Project Report 1E-98 HARD ROCK TUNNEL

When copying from the report, the source should be stated.

Trondheim, September 2000

Contact address: Amund Bruland

Telephone +47 73 59 47 37 Fax +47 73 59 70 21

0.1 PROJECT REPORTS ABOUT HARD ROCK TUNNEL BORING

The report treats the following items:

• Chapter 1 describes a system for recording, averaging and normalisation of ma-

Appendix A shows a list of previous editions of the HARD ROCK TUNNEL

Use of the Estimation Models

• Preliminary and feasibility studies

• Estimating net penetration rate and cutter wear

0.2 FIELD PERFORMANCE STUDIES

• To improve the tunnel boring operations at the site.

Figure 0.1 Sectioning of the back-mapping and follow-up database.

• Net penetration rate (mm/rev and m/h)

An example of a shift log is given in Appendix D.

1.1 NET PENETRATION RATE

♦ Higher average cutter thrust

Im = average net penetration rate (m/h)

1.2 GROSS THRUST

It may however be necessary to instrument individual cutters to measure the cutter

The applied hydraulic pressure is recorded continuously by the onboard computer or