04-herrenknecht-ITA TC-slide Format - Herrenknecht AG 20 - 04 - 06

ITA/AITES
ITA/AITES – Training Course

TUNNEL ENGINEERING
Mechanized Tunnelling.
Full face tunnel boring machines,
Herrenknecht AG.
Prepared by “Dipl.- Ing. Karin Bäppler,”
Séoul - 2006
April 20, 2006 1/99

Index
1
Table of contents
2
Hamburg / Germany
3
Moscow -Lefortovo / Russia
4
Westerschelde / The Netherlands
5 Kuala Lumpur / Malaysia
2/99
Index
6
Shanghai / China
7
Paris / France
8
Botlekspoortunnel / The Netherlands
9
Madrid / Spain
10 Islisberg / Switzerland
3/99
Index
11
Gotthard / Switzerland
12
Atlanta / US
13
Lötschberg / Switzerland
4/99
Table of contents.
1 Soft ground TBMs
 Slurry supported tunnel face (Slurry Shield, Hydroshield,Mixshields).

2  Convertible TBMs.
 Earth Pressure Balance Shields.
3
 Hard Rock TBMs
4  Shielded Hard Rock TBMs (Single Shield TBMs, Double Shield TBMs).
 Gripper TBMs.
Table of contents 5/99

Range of products.
6/ 99
Soft ground TBMs (EPBs and Mixshields)
Soft ground TBMs 7/ 99

Mixshields.
EPB
OPEN SHIELD
HARD ROCK
SLURRY

Mixshield. Safe tunnelling in varying ground
conditions.

General layout Mixshields.

Real performed operational pressure during
excavation. Real Performed Operational
Pressure During Excavation
15,0
HALLANDSAS
LAYOUT
WESTERSCHELDE
- MIXSHIELD ø 11,4m - 13,0
SAND; CLAY
12,5
WESERTUNNEL
MÜLHEIM
- MIXSHIELD ø 11,4m -
GRAVEL; CLAY; BOULDERS
SANDSTONE; CLAYSTONE
10,0
HAMBURG
GRAUHOLZ
GRAVEL; CLAY; BOULDERS
SAND; GRAVEL; MOLASSE 8,5
[bar]
7,5
HERA HAMBURG SYDNEY
- MIXSHIELD ø 6,0m - - MIXSHIELD ø 10,4m -
SAND; GRAVEL
SANDSTONE; CLAY 5,5
5,0
4,0
3,5 3,5
2,5
2,5
0,0
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
00
01
02
03
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
20
20
20
20
DIVERS
ENGAGED

Hamburg, Germany.
4th Elbe River Tunnel.
1  Diameter: 14,200 mm
 Cutterhead power: 3,400 kW
 Tunnel length: 2,560 m
 Geology: Gravel, silt, sand, boulders
2  Contractor: Bilfinger Berger AG
Dyckerhoff & Widman AG
Heitkamp GmbH
HOCHTIEF AG
3 Philipp Holzmann AG
Wayss & Freytag AG
Ed. Züblin AG
4
Hamburg/ Germany 12/ 99

Connection to the existing tunnel tubes.

Demanding geology under the Elbe River.

Jaw Crusher.
Capable of handling boulders up to Ø 1,200 mm.
 Crusher jaws can apply force 900 kN.

 Replaceable jaws.
 Crusher grill size 200 mm.

One of the major technical innovations.
Cutting Tool Change under atmospheric pressure.
 Access to the main arm of the
cutting wheel under atmospheric
pressure.
 Operator undertakes maintenance
procedure’s without the risk of
having to work at the tunnel face.
 Back loading cutting tools.

Procedure Cutting Tool Change.
 Each disc cutter is mounted in a pressurized housing with a hydraulically operated

gate valve.
 Removing of mounting bolts.
 Withdrawal of disc cutter.
 Closing of gate valve to seal the housing off from the face.
 Disc cutter removal with a crane attachment.

Torque reduction with active center cutter.
160
140
158 %
120
100
100 %
80
60
40
20
0
 Without the center cutter
 With the center cutter

Erector (telescopic rotating frame).
 Providing rotation of
+/- 210 degrees.
 18 to 20 tons segments are
held using 3 automated
vacuum plates.

Segmental lining, 4th Elbe Tunnel Tube. Segmental
Lining.

The worlds greatest Mixshield on mission
breakthrough in Moscow.
 Cutterhead power: 3,200 kW + 315 kW
2  Geology: fine to coarse sand,

clay, limestone
(medium strength,
3
partially very fissured)
 Contractor: AO Corporation Transstroy
Lefortovo/ Moscow 21/ 99

Outstanding record.
2,222 m tunnel in only 15 months.

3rd use for the Silberwaldtunnel in Moscow.
 Diameter: 14,200 mm
 Tunnel length: 2 x 1,505 m
 Geology: fine to coarse sand,
clay, limestone
(medium strength,
partially very fissured)
 Contractor: AO Corporation Transstroy

Tunnel Cross Section.
Silberwald, Moscow.

Westerschelde. The Netherlands.

(with 2 machines)
2 Segmental lining
 Geology: Sand, clay

Support pressure up to
8.5 bar
3
 Contractor: - Bam Infrabouw B.V.
- Franki nv
- Hejmans nv,
4 - Philipp Holzmann AG
- Voormolen Bouw B.V.
- Wayss & Freytag AG
Westerschelde/ Netherlands 25/ 99

Westerschelde. The Netherlands.

Geology Westerschelde.
Pressures up to 8.5 bar.

Machine features against clogging behavior.

Working in up to 8.5 bar pressure.
 5 operations under saturation.

 Total time under saturation:
more than 40 days.
 Decompression times with operating
pressures up to 6.9 bar have been in each
case 4 days.
 6 operations for inspection with mixed gas
have been realized.
 1,652 hrs under pressure with 546 man-
lockings.

Two Mixshields for SMART Tunnel project in
Kuala Lumpur, Malaysia.
5
Kuala Lumpur/ Malaysia 30/ 99

An innovative idea.
Multi-function tunnel in Kuala Lumpur.

Tunnel route SMART, Kuala Lumpur.
 North TBM Drive, S-252  South TBM Drive, S-253

 Tunnel length: 5,400 m  Tunnel length: 4,050 m
 Contractor: Wayss & Freytag AG  Contractor: MMCEG-Gamuda JV

Feature of karstic limestone bedrock.

Exposed karstic rockhead during tin mining.

Two giants Ø13.21m Mixshields S-252 / S-253.
Concentrated power for Kuala Lumpur.
 Tunnel length: 5,400 m (W&F); 4,059 m (MCC-Gamuda)

 Geology: Limestone, sand, marble
 Contractor: Wayss & Freytag AG, MMC-Gamuda

Possible drillings for karstic zones.
Mixshield Kuala Lumpur.

Efficient mining in soft ground.
Soft ground tools with wear detection system.
 Enables current information about cutting tool wear.

 Economical tool change.
 Damage limitation on steel structure.

Up to date largest TBM worldwide.
Mixshield - Cutting wheel Ø15.43 m.
5  Diameter: 15.43 m
 Power: 3,500 kW
 Geology: Sand, clay and
6 rubble
 End user: Shanghai Metro
Shield Machine
7 Equipment and
Engineering Co., Ltd.
Shanghai / China 38/ 99

Two Ø15.43 m Mixshields for Shanghai (China).
Bridge
2 Tunnels
Changjiang Under River Crossing Tunnel Project.
Shanghai.

Large tunnel cross section:
Changjiang under River Tunnels, Shanghai.

Manufacturing of the TBM. Shanghai Changjiang
Under River Crossing Tunnel Project.

Manufacturing of the TBM. Shanghai Changjiang
Under River Crossing Tunnel Project.
Shanghai/ China 43/ 99

Shanghai/ China 44/ 99
Herrenknecht in China.
Current projects
1 S-169 Beijing 1 x EPB-Shield Ø 6,190mm Metro
2 S-242, S-243 Guangzhou 2 x EPB-Shield Ø 6,250mm Metro
4 S-254 Beijing 1 x EPB-Shield Ø 6,250mm Metro
5 S-261 Guangzhou 1 x EPB-Shield Ø 6,250mm Metro
7 S-282, S-283, Tianjin 3 x EPB-Shield Ø 6,390mm Metro
S-284
8 S-285, S-291, Beijing 3 x EPB-Shield Ø 6,250mm Metro
S-294
10 S-301 Xinjiang 1 x Double Shield TBM Ø 6,705mm Water
11 S-317, S-318 Shanghai 2 x Mixshield Ø 15,430mm Road
12 S-329 Guangzhou 1 x EPB Shield Ø 6,250mm Metro
13 S-335 Hongkong 1 x Mixshield Ø 7,990mm Railway
15 S-344, S-345 Guangzhou 2 x Mixshield Ø 6,250mm Metro
17 S-349, S-350 Nanjing 2 x Mixshield Ø 14,930mm Road

Herrenknecht in China.
Finished projects.
19 S-106 Shanghai 1 x EPB-Shield Ø 2,715mm Water
22 S-190 Nanjing 1 x EPB-Shield Ø 6,390mm Metro

23 S-195, S-217 Nanjing 2 x EPB-Shield Ø 6,390mm Metro
24 S-199 Hongkong 1 x Mixshield Ø 5,150mm Water
25 S-206, S-207 Shenzhen 2 x EPB-Shield Ø 6,250mm Metro
26 S-225, S-226 Tianjin 2 x EPB-Shield Ø 6,390mm Metro


30 S-259 Changjiang 1 x Mixshield Ø 6,570mm Sewage

Socatop, Paris.
Socatop, Paris/ France 48/ 99

Socatop. Road Tunnel for the A86.

Socatop. Tunnel cross section.
Exhaust
Exhaust

Socatop-Paris, France.

Segmental lining
 Geology: Sand, lime, clay, marl,

chalk
 Contractor: - Cofiroute

Geology Socatop.
Open
Mode EPB Slurry Slurry EPB

Conversion Mixshield mode to EPB mode & vice
versa.

EPB-Shields.
Through soft ground with Earth Pressure.

General layout EPB-Shield.

Face Pressure Control.
Increase / Lowering of Shield Advance Rate
Increase / Lowering of
Screw Conveyor Discharge Rate
Water Earth
Pressure

EPB Soil-requirements.
To be useable as support medium, the soil has to fulfil following

requirements:
 Capability to extrude.
 Cohesive and plastic.
 Soft to stiff consistency.
 Lower inner angle of friction.
 Low water permeability.
 Good elasticity.

EPB Choice of conditioning.
If the soil requirements are not existing, the soil has to be conditioned.
The conditioning is dependent on following soil parameters:
 Grain size distribution.

 Water content, w (%).
 Liquid limit, wL (%).
 Plasticity Index, IP and
 Consistency Index, IC.

EPB Injection material.
 Bentonite.
 Water.
 Polymers.
 Foam.
The initial state of the soil should be kept unchanged as possible; the
consistency of the soil should guarantee the transport to the disposal
site and should be economical.
59/ 99
Foam injection points.
60/ 99
Advantages of conditioning.
 Low density.
 Optimum mixing with soil.
 Reduction of internal friction.
 Reduction of cutting wheel torque.
 Reduce soil adhesion to metal of
shield/ cutting wheel.
 Reduce soil permeability.
 Reduction of wear.
 Higher temporary face stability.
61/ 99
Botlekspoortunnel Railway Tunnel, The
Netherlands.

Segmental lining
6  Geology: Clay, coarse sand, gravel
 Contractor: Ballast Nedam Beton

en Waterbouw BV
7
Hollandsche Beton-en
Waterbouw BV
Strukton Betonbouw BV
Van Hattum en
Blankevoort BV
8 Wayss & Freytag AG
Botlek/ Netherlands 62/ 99

Botlekspoortunnel.
Two Tubes under the river “Oude Maas”.

Grain size distribution curve Botlek.

Piston pump for pressure control.

Pressure reduction along the screw.
S-144 Botlekspoortunnel
Strecke 1 - Ring 220: Förderschneckendruck und Druckabbau
3,0 0,5
2,7
Pressure at screw bottom
2,4 0,4
Erddruck Schneckenförderer [bar]
2,1
Druckabbau pro Wendel [bar]

1,8 0,3
1,5
Pressure reduction per spiral
1,2 0,2
0,9
0,6 0,1
0,3
Pressure at screw gate
0,0 0

Belt weighing system.

Laser scanner for muck control.

M-30 Madrid, Spain.
9
 Cutterhead Power: 12,000 kW

Segmental lining
10  Geology: Clay, sandy clay, gypsum
 Contractor: Necso/ Ferrovial Agroman

11
12
Madrid / Spain 69/ 99

Geology along the tunnel alignment.
M-30 Road Tunnel Madrid.

Highest torque ever installed in a TBM.
125,268 kNm, EPB-Shield M-30 Madrid.

Torque development EPB / Mix.

Hard Rock TBMs.
Single Gripper-TBM:
S-155 Tscharner,  9.53 m
Double Gripper-TBM:
S-96 TBM 3000,  3.00 m
Shielded-TBM with articulation joint:

S-163 Sörenberg,  4.56 m
Double Shield-TBM:
S-153 La Réunion,  3.80 m
Hard Rock TBMs 73/ 99

Single Shield TBM.

Excavation and muck transport.

Excavation and muck transport.

Islisberg, Switzerland.
Single Shield TBM.
 Diameter:
9
11,805 mm
 Tunnel length: 1 x 4,680 m, 1 x 4,645 m

Segmental lining
10  Geology: Molasse (Limy siltstone

with varying clay and sand
content and sandstone)
11  Contractor: - Marti AG
12
Islisberg / Switzerland 77/ 99

Tunnelling rates, Islisberg.
First Drive (Tunnel 1, West).

Breakthrough West Tunnel Islisberg.
4,680 m in 54 weeks, single-shift operation.

Gripper TBMs.

Gotthard Base Tunnel, Switzerland.
4 x Gripper TBMs.
9  Diameter:
 CH Power:
8.89m/ 9.33m/ 9.58m.
3,500kW
 Weight: 3,200t
 TBM length: 410m
11  Tunnel length: - Lot Bodio-Faido: 28.75km

- Lot Faido-Sedrun: 23.80km
- Lot Amsteg-Sedrun:22.70km
 Geology: Granite, Gneiss, Schist

11  Contractor: - Zschokke Locher AG
- Alpine Mayreder Bau GmbH
- CSC
- Impregilo
12
- Hochtief AG
- Murer AG
- Strabag AG
Gotthard / Switzerland 81/ 99

Crossing of the ALPS.
4 Gripper TBMs for a total of 75km of tunnel.

TBM-Advance with Herrenknecht machines
through the Gotthard Massif.

Fault zone Bodio South.

Current situation Bodio (March 2006).
S-210 East Tunnel

11,402 m of 13,955 m
already excavated.
S-211 West Tunnel

12,106 m of 14,795 m
already excavated.

Current situation Amsteg (March 2006).
S-229 East Tunnel

9,927 m of 11,350 m
already excavated.
S-230 West Tunnel

8,441 m of 11,350 m
already excavated.

S-288 / S-289
West Area CSO Tunnel Atlanta.

9
Diameter: 8,230 mm
1 x 6,800 m
10  Geology: Gneiss, Granite

 Contractors: Obayashi
Massana JV
11
12
Atlanta / USA 88/ 99

CSO Tunnel Atlanta.

TBM application for solid rock conditions.
Description of the Gripper technology.

Tunnel face at Lötschberg Steg.
Gneiss, granite, granodiorite.
13
Lötschberg / Switzerland 91/ 99

Lötschberg-Basistunnel (Switzerland).
Steg / Raron, Ø9.43m

Gripper TBM. Features.

Tunnel protection anchors.

Shotcrete Robot. L2.

Wire mesh erector.

View on back-up.

Thank you very much for your attention.
98/ 99

04-herrenknecht-ITA TC-slide Format - Herrenknecht AG 20 - 04 - 06

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

04-herrenknecht-ITA TC-slide Format - Herrenknecht AG 20 - 04 - 06

Uploaded by

Copyright:

Available Formats

ITA/AITES

ITA/AITES – Training Course

April 20, 2006 1/99

5 Kuala Lumpur / Malaysia

 Slurry supported tunnel face (Slurry Shield, Hydroshield,Mixshields).

Table of contents 5/99

Soft ground TBMs 7/ 99

Soft ground TBMs 8/ 99

Soft ground TBMs 9/ 99

Soft ground TBMs 10/ 99

Soft ground TBMs 11/ 99

Hamburg/ Germany 12/ 99

Hamburg/ Germany 13/ 99

Hamburg/ Germany 14/ 99

 Crusher jaws can apply force 900 kN.

Hamburg/ Germany 15/ 99

Hamburg/ Germany 16/ 99

 Each disc cutter is mounted in a pressurized housing with a hydraulically operated

Hamburg/ Germany 17/ 99

Hamburg/ Germany 18/ 99

Hamburg/ Germany 19/ 99

Hamburg/ Germany 20/ 99

2  Geology: fine to coarse sand,

Lefortovo/ Moscow 21/ 99

Lefortovo/ Moscow 22/ 99

Lefortovo/ Moscow 23/ 99

Lefortovo/ Moscow 24/ 99

 Tunnel length: 2 x 6,600 m

 Geology: Sand, clay

Westerschelde/ Netherlands 25/ 99

Westerschelde/ Netherlands 26/ 99

Westerschelde/ Netherlands 27/ 99

Westerschelde/ Netherlands 28/ 99

 5 operations under saturation.

Westerschelde/ Netherlands 29/ 99

Kuala Lumpur/ Malaysia 30/ 99

Kuala Lumpur/ Malaysia 31/ 99

 North TBM Drive, S-252  South TBM Drive, S-253

Kuala Lumpur/ Malaysia 32/ 99

Kuala Lumpur/ Malaysia 33/ 99

Kuala Lumpur/ Malaysia 34/ 99

 Tunnel length: 5,400 m (W&F); 4,059 m (MCC-Gamuda)

Kuala Lumpur/ Malaysia 35/ 99

Kuala Lumpur/ Malaysia 36/ 99

 Enables current information about cutting tool wear.

Kuala Lumpur/ Malaysia 37/ 99

Shanghai / China 38/ 99

Shanghai / China 40/ 99

Shanghai / China 41/ 99

Shanghai / China 42/ 99

Shanghai/ China 43/ 99

Shanghai / China 45/ 99

21 S-181, S-182 Guangzhou 2 x EPB-Shield Ø 6,250mm Metro

22 S-190 Nanjing 1 x EPB-Shield Ø 6,390mm Metro

25 S-206, S-207 Shenzhen 2 x EPB-Shield Ø 6,250mm Metro

26 S-225, S-226 Tianjin 2 x EPB-Shield Ø 6,390mm Metro

28 S-236, S-237 Guangzhou 2 x EPB-Shield Ø 6,250mm Metro

29 S-240, S-241 Guangzhou 2 x EPB-Shield Ø 6,250mm Metro

Shanghai / China 47/ 99

Socatop, Paris/ France 48/ 99

Socatop, Paris/ France 49/ 99

Socatop, Paris/ France 50/ 99

 Tunnel length: 10,500 m