Underground Space Use: Analysis of the Past and Lessons for the Future Erdem & Solak (eds)

) 2005 Taylor & Francis Group, London, ISBN 04 1537 452 9

Shield tunneling technologies in Japan

T. Goto, T. Masaka, K. Miki & S. Takaku
Shield Tunneling Association of Japan, Tokyo, Japan

ABSTRACT: The Shield Tunneling Association of Japan, STA, was established in 1999, and its membership consists of 97 companies including leading general contractors, TBM and lining segment manufacturers. Fourteen proven and reliable shield tunneling methods have been registered with the association to date, and the association is helping to apply these shield tunneling methods to various projects and promoting widespread use of those methods. This paper introduces the history of shield tunneling methods in Japan and some of the latest shield tunneling technologies, focusing on the registered 14 shield tunneling methods.

OUTLINE OF THE ASSOCIATION

10000 9000 TEPCO Trans Tokyo Bay 8000 7000 Length, m 6000 5000 4000 3000 2000 1000 0 1990 1995 Completion year 2000 2005 Kozukue Main Trans Tokyo Bay Highway Imaigawa Reservoir NTT Edogawa KEPCO Gakuen Toyosaki KEPCO Gakuen Toyosaki TEPCO Ageo Nippa Suehiro Main

In recent years, use of underground spaces has been essential to the construction of urban infrastructure. Shield tunneling methods have been gaining increased importance as a means of creating underground spaces. The Shield Tunneling Association of Japan was established in 1999, and its membership consists of 97 companies including leading general contractors, TBM and lining segment manufacturers. It has registered 14 reliable, time-tested and state-of-the-art shield tunneling technologies and methods. It has been collecting and organizing management, and thereby helping apply specific methods and enhancing and promoting shield tunneling technologies. 2 GENERAL

Figure 1.

Example of long distance tunnel.

In 1939, shield tunneling was used successfully for the first time to construct a circular railway tunnel in Japan. In the 1960s, shield tunneling began to be used for various infrastructure projects in urban areas, and the open shield method had its heyday until the 1980s. The period from 1980 to 1990 saw a transition from open TBM to closed TBM such as earth pressure balance shield machines developed in Japan. At present, 98 percent of TBM machines used in Japan are closed type. During the peak period in the 1980s, as many as 300 contracts were awarded each year for shield tunneling projects, and marked progress was made in infrastructure development. Today, although the number of shield tunneling contracts awarded each year declined to around 150, the contract requirement is getting tougher such as deep tunnel under 1 MPa water pressure, highway tunnel of 16 m diameter, long distance drive (9 km) for trans

Tokyo Bay tunnel, and increase of sections of rectangle and multi-circles. One of examples is shown in Figure 1. STA is providing technical support to the challenging projects with the registered 14 shield tunneling methods, and contributing to the development of Japans shield tunneling technology. 3 FOURTEEN SHIELD TUNNELING METHODS

The 14 shield tunneling methods are registered to the Shield Tunneling Association of Japan and the details of each method are classified into tunneling technology, multiface, non-circular, special technique, and lining technologies; and described as follows with figures for each.

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3.1

Tunneling technologies

3.1.1 DK shield method The DK Shield Method controls muddy soil pressure for tunnel excavation in three phases to minimize disturbance to the ground. Mud making agent is injected into soil excavated by a cutter. The excavated soil is then kneaded forcefully with the agent using kneading blades and changed to muddy soil with plastic fluidity and impermeability. Kneading chamber and screw conveyor are filled with muddy soil. Then, muddy soil is pressed by the thrust of a jack to resist groundwater pressure and earth pressure, providing face stability. Muddy soil pressure is constantly monitored using pressure gauges attached to the bulkhead. Shield driving is controlled by changes in the rate of shield advance and the rotational speed of the screw conveyor so that muddy soil pressure becomes equivalent to the total of earth pressure at rest and water pressure. It was experimented under water pressure of 0.7 MPa and concluded that it can be applied in underground as deep as 50 m. 3.1.2 Rheological foam shield tunneling method The Rheological Foam Shield Tunneling Method is to excavate a tunnel while injecting foams into the face and the chamber. The foams are generated by special foaming agent. The tiny foams with properties similar to those of shaving cream improve the fluidity and the watertightness of excavated soil. Foams can also prevent the soil from sticking inside of the chamber. This enables smooth tunnel driving while maintaining face stability. In addition, the removed soil with foams can be defoamed and put back to the state as before foam injection. Then excavated soil can be easily transported and disposed of. Thus, the method also has economic merit.

The Rheological Foam Shield Tunneling Method has been adopted on 404 projects, constructing a total length of 412 km as of April 2004. 3.1.3 Chemical plug shield method An additive and the main chemical agent, CP-M, are mixed with the excavated soil in the chamber. Then, the assistant chemical agent, CP-S, is injected into the screw conveyor to create a cut-off plug from improved

Figure 3.

Rheological foam shield tunneling method.

Figure 2.

DK Shield Method.

Figure 4.

Chemical plug shield method.

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soil. This enables safe and accurate excavation in waterbearing gravelly soil under high water pressure, up to 1.0 MPa, while controlling face pressure and preventing face collapse due to blow and other soil disturbances. The CP-M is added to conventional EPBs additive at the plant. The plant for the CP-S may be located in the tunnel. The excavated soil mixed with CP-M is mixed with CP-S and agitated in the screw conveyer, and rapidly changed into improved soil to form the cut-off plug. 3.2 3.2.1 Multiface

or horizontally could offer tunnels of diverse cross section other than a circular section. This enables simultaneous construction of upper and lower tunnels at a site with limited land under a narrow road by vertically connecting tunnel cross sections occupying a small area. Even in cases under restrictions on vertical space due to existing structures, a multi-circular-face shield method using horizontally connected cross sections can be adopted. Tunnel cross sections fit for the construction condition or tunnel use can be provided efficiently. 3.2.3 DOT tunneling method The DOT Tunneling Method is applied for an earth pressure balance shield machine with interlocking spoke-equipped multiple cutters that are positioned in the same plane to construct tunnels of double or triple cross sections.Adjacent cutters rotate in the opposite directions to avoid touching or smashing one another and are thus controlled synchronously. Rolling of the shield machine is controlled by component force of thrusting jack by shifting along the circumference of the machine, and rolling control jacks placed on the longer sides of the machine. The DOT shield machine is equipped with cantilever-arm type erector to erect joint and panel segments, so it provides wide working space.

Horizontal and vertical variation shield method Cross section can be changed continuously from horizontal to vertical multi-circular shape or vice versa. The cross articulation system enables free control of machine steering and orientation, and continuous change of multi-circular cross section from horizontal to vertical alignment or vice versa. The cross articulation system articulates multiple front bodies of a shield machine in reciprocal directions and make respective bodies advance in different directions. The system enables shield machine to generate rotating forces and advance so that the tunnel spirals. The machine can be divided. Therefore tunnel can be separated without intermediate shaft. 3.2.2 Multi-circular face shield method The Multi-circular Face Shield Method places 2 or 3 cutter heads attached to shield machines in such a way that one locates ahead of others and overlaps each other. Connecting double or triple circular sections, or sections of different cross sections vertically

Figure 6.

Multi-circular face shield method.

Figure 5.

Horizontal and vertical variation shield method.

Figure 7.

DOT tunneling method.

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Figure 9. Figure 8. DPLEX shield method.

Wagging cutter shield method.

The method provides a more reasonable shape with smaller unnecessary space in the cross section of railway and highway tunnels than circular shield tunneling methods. 3.3 Non-circular

3.3.1 DPLEX shield method Supporting the cutter frame eccentrically at the ends of multiple crank shafts, and rotating the shafts in the same direction cause the cutter to move in a circle along the inside perimeter of tunnel cross section and create a cross section with a shape similar to the cutter. It means that this method creates tunnels of any cross section. To stabilize the face, the EPB method, which has been adopted for circular shield machines and proofed highly reliable, is basically employed. The cross-roof bit unique to this method enables cutting in all directions with the rake and relief angles being equal to each other. A cutter with short turning radius requires low torque at the cutterhead. Multiple drive motors can be integrated into a compact unit. Thus, the shield tunneling machine can be assembled, dismantled and transported easily. The advantage is greater for larger shield machines. A cutter with short turning radius means short bit sliding distance and reduces bit wear. Thus, tunnels can be excavated the length about three times that by conventional machines. The cutterhead drive motor is small enough to enable full-face soil stabilization from within the shield machine. Soil in curved sections or in the vicinity of the tunnel can be stabilized from within the machine. 3.3.2 Wagging Cutter Shield Method Wagging Cutter Shield Method enables to excavate various cross sections such as circular, multi-circular and rectangular sections by wagging cutter. Cutters are wagged by reciprocating motion of hydraulic jacks. Thus, the driving mechanism is simple

Figure 10.

JIYU-DANMEN shield method.

and the weight and length of the tunneling machine can be reduced. The rotation of the cutters and the expansion and contraction of overcutters are automatically controlled to enable accurate excavation of corners of the cutting face in case of non-circular shape. Long stroke overcutters, essential to the non-circular wagging cutter shield method, are required to have higher durability and reliability than ordinary cutters. The newly developed high-performance spike bit is capable of penetrating and cutting the earth when the overcutter is expanded or contracted, and before and after the cutterhead is wagged. 3.3.3 JIYU-DANMEN shield method One of the major features of the JIYU-DAMMEN Shield Tunneling Method is its capability of excavating tunnels with various cross-sectional shapes such as oval, horseshoe and rectangle. Adopting planetary cutters enables free selection of the tunnel cross sections. The main cutter excavates

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Figure 11.

Enlargement shield tunneling method. Figure 12. Rotating shield method.

the circular section at the center of the face, and the multiple planetary cutters excavate surrounding areas. The planetary cutters, while rolling themselves, rotate along the perimeter of the rolling main cutter. The orbit of the planetary cutters can be changed freely by adjusting the angle of swing arms attached to them. Thus, various cross sections can be easily created. Since a horseshoe-shape, oval or rectangular crosssectioned tunnel can be designed, a large crosssectioned tunnel may be excavated in the ground which is restricted in width and/or depth. 3.4 Special technique

3.4.1 Enlargement shield tunneling method This method allows launching the Enlargement Shield from the launching base at an arbitrary location in an existing shield tunnel and excavates the tunnel longitudinally to enlarge the cross section of the tunnel. First, base for launching circumferential shield is constructed and the circumferential shield excavates the earth around the existing tunnel. Enlargement shield machine is then assembled in the void created by the circumferential shield. Enlarged tunnel is constructed by the enlargement shield machine which runs outside the existing tunnel along the direction of the tunnel axis. By the method, cross section can be enlarged for a desired length according to special need. The method offers even greater economy and shorter construction period in tunneling at greater depths. 3.4.2 Rotating shield method The Rotating Shield Method enables to change the direction of the tunnel driving in such a way that spherical part with cutter rotates and launches out of it. It is called Horun. Using similar technique, for long distance driving, cutter bits are replaced inside the machine by rotating the spherical part so that the cutter faces inward. It is called Kurun. In case of Horun method, excavation is carried out by a single shield machine continuously from the

ground surface first driving in the vertical direction then in horizontal for the adit. Separate construction of shaft by d-wall or caissons, which is necessary for conventional shield tunnel, is not required, so it contributes to easier construction, shorter construction period and reduces cost. Similarly, this mechanism enables a single shield machine to continuously excavates a tunnel, curving horizontally at a right angle. The machine is highly effective in underground spaces below congested intersections or occupied by buried structures where no vertical shaft can be driven for turning the shield machine. In case of Kurun, the machine is effective in excavating long distances continuously. Cutter bits can be replaced simply by rotating the cutter head. The method has eliminated ground improvement and other measures required by conventional methods. It is especially beneficial for deep tunnel. 3.4.3 Mechanical shield docking method 2 machines from both sides are connected mechanically underground without ground improvement and inflow of earth and ground water. One machine equips insert ring and another its receiver. Docking and dismantling of conventional shield machines has been done in narrow space where the ground was exposed. The Mechanical Shield Docking (MSD) Method enables steel rings to directly support earth and water pressures, and ensures safe and reliable work without exposing the ground. Docking point can be selected freely without any restrictions of surface traffic or underground utilities. It is possible even under seabed. The MSD Method causes neither ground settlement nor uplift and involves no surface work, so it has no impacts on surface traffic or the neighboring environment. The MSD Method requires no auxiliary measures and enables easy mechanical shield docking, so it

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Figure 14.

P&PC segment lining method.

Figure 13.

Mechanical shield docking method.

achieves a reduction of construction time, compared to conventional methods. Costs can be reduced because no auxiliary measures for stabilizing the ground and shaft are required. 3.5 Lining technologies

Figure 15.

Extruded concrete lining method.

3.5.1 P&PC segment lining method The P&PC Segment Lining provides a lining ring of post-tensioned prestressed concrete structure by assembling a segmented concrete ring, giving it tension, and fastening it by inserting a prestressing single strand into the sheath that has already been embedded in the precast concrete segment. Because an unbonded prestressing strand with low friction loss between the prestressing steel and sheath is used for the prestressing strand, sufficient prestress can be introduced by applying tension to only one position on the whole circumference. Furthermore, by using a combined anchoring device made of cast iron that has the tension side and fixing side integrated into one piece (X anchor) by embedding it in the segment, the reinforcement in the segment can be simplified and buildability of tensioning can be improved. 3.5.2 Extruded concrete lining method Extruded Concrete Lining Method is to construct the lining by in-situ concrete at shield tail instead of precast segment. As the shield advances, fresh concrete is extruded and pressed considering groundwater pressure

and earth pressure in such a way that it prevents loosening of the surrounding earth, and the lining closely contacted to the earth is created. This method allows flexible choice of lining based on the site conditions, out of reinforced concrete, nonreinforced concrete, fiber-reinforced concrete, steelreinforced concrete and prestressed concrete. 4 CONCLUSIONS

14 shield tunneling methods registered to the STA were outlined. Key words describing current Japanese shield tunneling are deep, large diameter, long driving, and various sectional shape. It is considered that this trend will continue. The STA intends to play a role for consultation to difficult projects using the 14 registered methods. Meanwhile Japanese shield tunneling technologies have been mainly applied domestically. The STA considers the technology to be put on the world map and applied for the prime sponsor of ITA. The authors hope that we are contacted to provide the quality of the Japanese shield technologies.

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