principles for tunnel design 20th to 21st april 2017 kuala ... · pdf fileherrenknecht asia...

Principles for Tunnel Design

20th to 21st April 2017– Kuala Lumpur

Mechanized Tunneling (TBM and Support Systems) Thorsten Tatzki

Herrenknecht Asia Headquarters Pte. Ltd.

2 Principles for Tunnel Design 20th to 21st April 2017– Kuala Lumpur

Introduction: General Overview

Shield Machines and Tunnel Boring Machines

Slurry Shield/Mixshield

Gripper TBM Single Shield TBM Double Shield TBM

EPB Shield Multi-mode TBM


Outline of Lecture

Selection of Tunnelling Machines

DAUB Classification Scheme

Geotechnics

Lining / Support

Influencing Aspects

Key Elements of Machine Design

Mechanized Tunnelling for Rock

Gripper

Single Shield

Double Shield

Mechanized Tunnelling for Soil Conditions

Earth Pressure Balance Shield Machines

Slurry Shield Machine / Mixshield Machines

Multi Mode Machines

Important Technical Trends

Literature / Links


Selection of Tunnelling Machines


Classification Scheme according DAUB for all Type of Tunnelling Machines

Rock

Soil/ soft ground

Source: DAUB Recommendations for the Selection of Tunnel Boring Machines (2010-10)

Deutscher Ausschuss fuer unterirdisches Bauen: DAUB Established in December 1972, the German Tunnelling Committee works on the development and standardization of techniques in underground construction.

Selection of Tunnelling Machines - DAUB


Selection of Tunnelling Machines - Geotechnics

General information:

Geological longitudinal profile with vertical alignment of the tunnel (max./min. gradient) and borehole locations

Layer structure & Groundwater conditions (max./min. groundwater pressure during construction)

Horizontal alignment (max./min. radius) of the tunnel with borehole locations

Details about the soil layers:

Grain size distribution curves

Specific weights / ’

Shear parameters: , c, cu

Permeability k

In case of fine soil: clay mineralogy and consistency (Atterberg Limits)

In case of granular soil: Quartz content

Modulus of elasticity Es

Possible existence of boulders: rock type, expected amount, expected sizes, UCS, quartz content, CAI

In situ stress situation:

Earth pressure coefficient K0


Selection of Tunnelling Machines – Lining / Support

Methods of supporting the ground and holding water at the face Source: Mechanised Shield Tunnelling

Possible types of lining in shield tunnelling Source: Mechanised Shield Tunnelling


Selection of Tunnelling Machines – Key Elements of Machine Design

Design of shield structure

Support pressure calculation

Torque calculation

Thrust force calculation

Wear prognosis

GEOTECHNICS

GEOLOGY + HYDROGEOLOGY



Interface Ground & TBM: support pressure

t

R

G

S

SCHILD

GOK

p(t)

D

b

R

G

90

E

F

E

G

F+K

R

K

SILO

ERDKEIL

z1

tw

pLPz2

GW

p(t)

Some important questions:

Where is highest overburden?

Where is highest water level above crown?

Where are the highest surface loads?

Lowest inner friction angle?

Lowest cohesion?

Foundation loads?



Interface Ground & TBM Shield Loads

Vertical earth pressure (crown)

G

k = 6 MN/m3

Vertical water pressure (crown)

Vertical earth pressure (invert)

Vertical earth pressure (invert)

Horizontal earth pressure

Horizotal water pressure

External loads:

Water and earth pressure

Rock burst, Swelling pressure, Squeezing pressure

Steering movements

Buoyancy

Internal loads:

Pressure on bulk head

Thrust forces

Erector and ring built

Weight of the components (drive, bridge … )

Grease pressure (tail skin sealing)



Friction of the shield coat MW 5,0 2 HVlr

Thrust resistance of cutting edge schW tpr sch 2

Cutterhead thrust

Drag force tailskin seal SSWF sTübbing PD *

Drag force back-up system

Support pressure

Force of thrust cylinders W SPNLSBASchM FFFWWW

BAW maximum tool thrust or thrust of displacement cylinders

NLF empirical value

SPF support pressure calculation

G

FSP WM

WBA WNL

Interface Ground & TBM Thrust Force



Weak rock:

High penetration

Large “crushing zone”

with low thrust and

small angle

Hard rock:

Low penetration

Small “crushing zone”

with high thrust and

large angle

Interface Ground & Wear and Performance


Mechanized Tunnelling for Rock

14

Selection of Tunnelling Machines – Mechanized Tunnelling for Rock

Machine belt

Machine support

Cutterhead

Muck ring

Buckets

Roof shield

Probe drilling unit

Thrust cylinders

Gripper shoes

Ring beam erector

Roof bolting unit

Gripper – Functional Principle

Principles for Tunnel Design 20th to 21st April 2017– Kuala Lumpur



Double Gripper TBM: S-96 TBM 3000, 3.00m

Single Gripper TBM: S-155 Tscharner, 9.53m

Double Shield TBM: S-153 La Réunion, 3.80m

Shielded TBM with articulation joint: S- 163 Sörenberg, 4.56m

Overview of the various machine systems of TBM with full face excavation Source: Hardrock Tunnel Boring Machines, 2008

16

1 2

3 4

5

6

7


Selection of Tunnelling Machines – Gripper

5. Wire mesh erector 6. Gripper plates 7. Automatic shotcrete robot

1. Cutterhead 2. Cutterhead support 3. Ring erector 4. Anchor drilling devices


Selection of Tunnelling Machines – Gripper / Mucking


Selection of Tunnelling Machines – Gripper / Cutting Wheel

Wear protection measures on cutterhead for blocky face conditions

Hardox-plates on entire surface

Protection blocks for cutter discs

Grain size limiters for buckets

Heavy bucket lips

Overcutting with shifting Gauge Cutter


Selection of Tunnelling Machines – Gripper / Tunnel Support


Selection of Tunnelling Machines – Gripper / Probe Drilling

Gripper TBM. Tunnel support in working area L1

Exploration Drilling

Drainage and Injection

Core Sampling

Geological Investigations


Selection of Tunnelling Machines – Gripper / Ring Beam Installation


Selection of Tunnelling Machines – Gripper / Wire Mesh Installation


Selection of Tunnelling Machines – Gripper / L2 Area (Shotcrete Robot)

Rock drills Shotcrete robot


Selection of Tunnelling Machines – Gripper / Performance

Rock support – The performance of the Gripper TBM depends mainly on the rock and support classes

Source: Schmid L.: Einsatz großer Tunnelbohrmaschinen verschiedener Bauart in der Schweiz – Leistungen und Wirtschaftlichkeit . In: Forschung + Praxis 29., 1980

Gripper TBM – Rock Conditions vs TBM Performance



Cutterhead

Muck ring

Buckets Shield skin

Thrust cylinders Backfilling

Machine belt Erector

Single Shield – Functional Principle


Selection of Tunnelling Machines – Single Shield / Swiss Double Lining

1. Withdrawal of the thrust ring and placing of the bottom segments.

2. Placing of the left and right tunnel side wall segments.

3. Placing of the crown segment and Spreading of the bottom segments

4. Placing of the key stone and Pushing forward of the thrust ring

Swiss Double Lining System With Thrust Ring.


Selection of Tunnelling Machines – Single Shield / Special Design

Thrust ring

Swing support roller

Single Shield TBM with Thrust Ring.

28


Muck ring

Cutterhead

Front shield

Stabilizers

Telescopic shield

Gripper shield

Gripper shoes

Erector

Torque cylinders

Main thrust cylinders

Machine belt

Auxiliary thrust cylinders

Double Shield – Functional Principle



Selection of Tunnelling Machines – Double Shield / Telescopic Shield

Thrust cylinders Open telescope


Selection of Tunnelling Machines – Double Shield / Logistic

DOUBLE-SHIELD

Tunnelling

Ring-building

Moving of machine

SINGLE-SHIELD

Tunnelling

Ring-building

13070 80 90 100 110 120

110 120 130

0 10 20 30 40 50 60

50 60 70 80 90 10010 20 300 40

Double Shield TBM / Single Shield TBM Logistics


Mechanized Tunnelling for Soil


Selection of Tunnelling Machines – Mechanised Tunnelling for Soil Conditions

Earth Pressure Balance Shield (EPB) Functional Principle.

Erector

Tunnel lining

Backfilling Tailskin Thrust cylinders

Screw conveyor

Mixing arms

Excavation chamber

Cutting wheel

Bulkhead

Air lock

Belt conveyor


Source: Mechanised Shield Tunnelling – B. Maidl, M. Herrenknecht, L. Anheuser

(1): Typical range for EPB with 30% fines (<0.06mm)

(2): permeability k < 10-5m/s k ~ d102 = 0.03mm2 = 10-5 m/s

(3): not under water pressure

Selection of Tunnelling Machines – EPB / Application Range


Ideal application on soils with:

High plasticity

Low inner friction

Low permeability

Aim is to maintain conditions with:

Good homogeneous pressure distribution & pressure variation

Low torque for low energy consumption

Low wear

Selection of Tunnelling Machines – Functional Principle EPB



1. Cutting Wheel

2. Main Drive

3. Excavation Chamber

4. Screw Conveyor

5. Erector

6. Shield

7. Thrust Cylinders

8. Belt Conveyor

9. Segment Feeder

10.Man lock

11.Backup Gantries / Bridge

12.Tunnel Wall

1

2

3 4

5

6

7

8

9

10 12

11


Support pressure regulation Advance speed (thrust cylinders)

Rotation speed screw conveyor



Support pressure regulation

Closed Mode

To avoid groundwater inflow

For unstable tunnel face

Settlement control



Selection of Tunnelling Machines – Mechanised Tunnelling for Soil Conditions

Bulkhead

Air cushion

Cutting wheel

Submerged wall

Air lock

Thrust cylinders

Tailskin

Backfilling or grouting

Erector Slurry circuit

Jaw crusher

Mixshield Functional Principle.


Source: Mechanised Shield Tunnelling – B. Maidl, M. Herrenknecht, L. Anheuser

Selection of Tunnelling Machines – Mixshield / Application Range


Selection of Tunnelling Machines – Mixshield / Filter Cake

Source: Pictures from Project S- 321 / Arge Nordsued Stadtbahn Koeln Face with Muck Cake / Geology Sand and Gravel

Trial: Muck Cake under compressed air


Selection of Tunnelling Machines – Slurry Shield Principal

Legend:

1. Tunnel face 5. Man lock

2. Cutting wheel 6. Support pressure

3. Excavation chamber 7. Regulation of support pressure

4. Pressure bulkhead 8. Support medium (slurry)

Slurry feed line

Slurry discharge line

Atmospheric area Pressure

area

1

2 3

4

5

6

7

8

One chamber system

Regulation and control of support pressure by flow of feed and discharge pump

Control of support pressure by pressure sensors

Closed type cutting wheel

System is typical for Japan due to geology

Partly clay suspension as support medium

Further development for cohesive soils led to principle of EPB-Shield


Selection of Tunnelling Machines – Mixshield Principal

Legende:

1. Tunnel face

2. Cutting wheel

3. Excavation chamber

4. Submerged wall

5. Excavation chamber

6. Air bubble

7. Pressure bulkhead

8. Man lock

9. Support pressure

10. Regulation of support pressure

11. Support medium

Pressure area Atmospheric area

Slurry feed line


10

1

2

3

4

5

6

7

8

9

11


Selection of Tunnelling Machines – Mixshield / Support Pressure

Pressure to be adjusted

0

1

2

3

0 10 20 30 40 50

Time (s)

Regulation of support pressure by air bubble (Mixshield)

Regulation of support pressure by pumps (Slurry shield)


Selection of Tunnelling Machines – Mixshield / Slurry Cycle

Slurry = Support of tunnel face and transport medium

Slurry circuit

Separation plant (Bentonite) slurry Mixing plant

Muck discharge Compressor

station

TBM

Compressed air regulation

Slurry feed line



Selection of Tunnelling Machines – Mixshield Design

1. Cutting Wheel

2. Bulkhead

3. Air – Cushion

4. Submerged Wall

5. Slurry Line

6. Stone-crusher

7. Feed Line

8. Erector

1

2

3

4

5 6

7

8


Selection of Tunnelling Machines – Multi Mode Machines

Single Shield TBM

Open Mode

Closed Mode

Slurry Shield EPB Shield

Conversion

integrated

modular


Selection of Tunnelling Machines – Convertible Machines

Modular system: Exchange of subassemblies or specific modules → conversion in shaft

Integrated system: Dual systems „on Board“ → conversion in tunnel


Selection of Tunnelling Machines – EPB / Open Mode Integrated Concept

Open Mode Screw conveyor in retracted position (reduced capacity) Center belt conveyor and muck ring in working position. Cutter head muck chutes completely installed

Closed Mode - EPB

Screw conveyor in extended position (maximum capacity)

Center belt conveyor and muck ring retracted.

Cutter head muck chutes partly dismantled.


Selection of Tunnelling Machines – Slurry / Open Mode Integrated Concept Special Variant Hallandsas

Open Mode

Closed Mode


Selection of Tunnelling Machines – EPB/Slurry – “Variable Density System”

Screw conveyor and slurry circuit can be permanently installed

Support mode can be gradually changed between EPB mode and Slurry Mode

Mucking can be done with Belt Conveyor or Slurry Circuit

EPB Mode

Slurry Mode


Selection of Tunnelling Machines – Variable Density System

I. Tunnelling through heterogenous ground condition

II. Combining Mixshield Mode and EPB Mode

III. Variation of the support medium density

IV. Variation of the muck transportation

Working Chamber with air bubble

Cu

tter

H

ead

Screw conveyor

Flushing box with drum crusher

High density slurry

Slurry pump

Bentonite feed line


Excavation Chamber


Selection of Tunnelling Machines – Slurry / EPB Application Range

60,0 20.0 6,0 2,0 0,6 0,2 0,06 0,02 0,006 0,002 0,001

100

90

40

30

20

10

0

80

70

60

50

Sieve Size

Fine Clay Silt Sand Gravel

Medium Medium Coarse Fine Coarse Fine Medium Coarse

EPB / MIX – Shield Range


Selection of Tunnelling Machines – 4 Operation Mode

MODE 1

EPB – closed mode

MODE 2

EPB – closed mode with

additional bentonite support

MODE 3

Mixshield mode with LDSM

(bentonite slurry )

MODE 4

HDSM - Mode

FACE SUPPORT

TRANSPORT OF EXCAVATED MATERIAL

EPB - TBM Mixshield – TBM

Variable Density - TBM

HYDRAULIC Transportation possible

DRY MUCKING

HYDRAULIC Transportation required


Selection of Tunnelling Machines – Mixed Face Conditions in the „KL-limestone.“

GW

Soft ground

Surface

Cavity

Sinkhole ! Overhang Collapsed

cavity

Hard rock


Selection of Tunnelling Machines – Variation Of Support Medium Density.

pSL – γld x h

pSL – γhd x h

LDSM - low density

support medium HDSM - high density

support medium

GW

Ground level

h

(γhd > γld )

FS_ HDSM FS _LDSM =

earth pressure

water pressure

Slurry pressure pSL

Pressure gradient with LDSM (γld )

Pressure gradient with HDSM (γhd )


Selection of Tunnelling Machines – Important Technical Trends

Larger TBM Diameters

Multi Mode Machine Development

2,5

3,5 3,54,0

5,5

7,5

11,0

14,0

11,0

0,0

2,5

5,0

7,5

10,0

12,5

15,0

17,5

Face

Pre

ssu

re [

bar

]

HERA HAMBURGMixshield, Ø 6.0m

SYDNEYMixshield, Ø 10.4m

MÜLHEIMMixshield, Ø 6.9m

GRAUHOLZMixshield, Ø 11.6m

HAMBURG4TH ELBTUNNELMixshield, Ø 14.2m

WESTERSCHELDEMixshield, Ø 11.4m

HALLANDSASMixshield, Ø 10.53m

ISTANBULMixshield, Ø 13.71m

DIVERS

ENGAGED

LAKE MEADMixshield, Ø 7.18m

1985 HERA 5.95m

1996 Sydney 10.70m

1997 Hamburg 14.20m

Concept St. Petersburg

19.25m

2006 Shanghai 15.43m

2013 Hong Kong

17.6m

Multi Purpose Tunnels

Higher Pressures


Literature / Links

B. Maidl, M. Herrenknecht, U. Maidl, G. Wehrmeyer: Mechanised Shield Tunnelling; 2. Edition, 2011

B. Maidl, L. Schmid, W. Rotz, M. Herrenknecht: Hardrock Tunnel Boring Machines, 2008

Deutscher Ausschuss fuer unterirdisches Bauen (DAUB): Recommendations for selecting and evaluating tunnel boring, 1997

German-Czech Scientific Foundation: Mechanised Tunnelling and Segmental Lining, 2009

Schmid L.: Einsatz großer Tunnelbohrmaschinen verschiedener Bauart in der Schweiz – Leistungen und Wirtschaftlichkeit . In: Forschung + Praxis 29., 1980

D. Kolymbas: Tunnelling and Tunnel Mechanics; 2. Edition, 2010

http://www.daub-ita.de/en/start/

https://www.ita-aites.org/en/

https://www.herrenknecht.com/en/home.html












58

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Principles for Tunnel Design

20th to 21st April 2017– Kuala Lumpur

principles for tunnel design 20th to 21st april 2017 kuala ... · pdf fileherrenknecht asia...

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