ТБМ упутсво

Disclaimer:
All information contained within these deliverables is copyright protected.

All rights reserved. All trademarks mentioned herein belong to their respective owners.
Information contained within these deliverables reflect the opinion of the authors only and shall
exclusively be used in connection with the performance of the EC project TUNCONSTRUCT.
The use for any other purposes is expressly forbidden.
Copyright 2005-2008 Technische Universitt Graz
New software. Calculation of foams dosage, including specifications and users manual
IP011817-2
TUNCONSTRUCT
Technology Innovation in Underground Construction
Integrated Project
Thematic Priority 3, NMP
D 2.5.2.7 New software. Calculation of foams dosage, including specifications

and users manual.
Due date of deliverable: December 2008 (month 40)
Actual submission date: 30.11.2008
Start date of project: 1. September, 2005
Duration: 48 months
Lead contractor: SIKA

Author(s): Jose Luis Rivas (SIKA), Oscar Videra (SIKA), Adela Jimenez. (SIKA)
Revision [version 1.0]
Project co-funded by the European Commission within the Sixth Framework Programme (2002-2006)
Dissemination level
Public
PU
PU
Restricted to other programme participants (including Commission services)
PP
Restricted to a group specified by the consortium (including Commission services)
RE
Confidential, only for members of the consortium (including Commission services)
CO
D2.5.2.7.pdf
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INDEX
Abstract..............................................................................................................................................4
1.
Introduction...............................................................................................................................5
2.
Objectives...................................................................................................................................6
3.
Framework of the program: FDC (Foam Dosage Calculation) OSCAR .............................7

3.1
3.2
3.3
3.4
3.5
4.
Foam design rules .............................................................................................................12

Specifications of foams.....................................................................................................14
Input required and calculation of Foam parameters .........................................................15
Final results.......................................................................................................................16
Future works .....................................................................................................................17
Users Manual .........................................................................................................................19

I.
INTRODUCTION...........................................................................................................19
II.
GETTING STARTED ....................................................................................................19
II.a
System requirements .....................................................................................................19
II.b
Running FDC OSCAR tool ...........................................................................................20
II.c
FDC OSCAR TUTORIAL .............................................................................................20
II.d
Data input .....................................................................................................................20
II.e
Data output ...................................................................................................................20
5. Contribution to the overall objectives of the TC project and quantification on the

expected benefit...............................................................................................................................23
6.
Conclusion ...............................................................................................................................24
7.
Further work ...........................................................................................................................25
8.
References................................................................................................................................26
Annex ...............................................................................................................................................27
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Index of figures
Figure 1 :
General perspective of OSCAR ..................................................................................5
Figure 2 :
Example of Laboratory Test .......................................................................................7
Figure 3 :
Initial menu. ................................................................................................................8
Figure 4 :
Input data. ...................................................................................................................9
Figure 5 :
Dosage Database.......................................................................................................10
Figure 6 :
Preview Report..........................................................................................................11
Figure 7 :
Foam generation........................................................................................................12
Figure 8 :
Foam circuit ..............................................................................................................13
Figure 9 :
Master Table. ............................................................................................................28
Figure 10 :
Program Welcome Window......................................................................................29
Figure 11 :
Entering titles. ...........................................................................................................30
Figure 12 :
Selecting soil and work conditions ...........................................................................31
Figure 13 :
Optimum foam dosage..............................................................................................32
Figure 14 :
Printing results ..........................................................................................................33
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Abstract
This document presents Deliverable 2.5.2.7, New Software. Calculation of foams dosage,
including specifications and users manual, regarding TUNCONSTRUCT, Subproject 2
Innovative Technologies, WP2.5 Impact on Environment, Task 2.5.2 Rules for choosing
additives according to geological and environmental criteria, for defining new additives and for
treatment of effluent pH, and has been prepared by SIKA.
The software details all results carried out on soils with Sika Foam 101, 102 and 103 TBM, using
OSCAR machine (Optimized Soil Conditioning Additive Reactor) and special with sand soil type,
as well as the test results.
The results obtained using OSCAR is presented distinguishing the different test pressure.
The result is in according with Deliverable 2.5.2.4 In-situ rules and tests for choice of additives
according to the geological conditions.
The report finishes with a Users Manual which explains the procedure to install and execute the
program. Finally, some conclusions and further steps of this research are presented.
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1. Introduction
OSCAR system (Optimized Soil Conditioning Additive Reactor) has been designed and built to
simulate EPBM behaviour in hyperbaric conditions, close to the working process. See Figure 1.
It is able to changing a series of parameters to see the influence of them:
Dosage of foam. Type of foam, air flow, volume of dissolution of the foam agents.
Type of soil. We had done test with five typical ground selected in accordance with the
different ground encountered during EPBM tunnelling works.
Pressure. Tests made with OSCAR in atmospheric conditions, 2 and 4 bars.
Once we have the soil treated with additives, in conditions of test set, we done a series of tests in
order to get as much information as possible from the effect of additives. Some special tests have
been carried out to assess the global behaviour:
Density test
Slump test
Adhesion test
Screw Conveyor sample
Permeability
Data recorded by PC (Torque, intensity and frequency of motor).
All of this translates into more than 500 tests. Data of these tests are used for the creation of a
database from which we can draw the following conclusion: assess the quantity and type of
additive to be used regarding the geological conditions in soil of a particular underground
construction project.
Figure 1 :
D2.5.2.7.pdf
General perspective of OSCAR
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2. Objectives
The objective of this research project is to present Software to calculate foams dosage according to
lab test results obtained of the study of OSCAR Machine (Optimized Soil Conditioning Additive
Reactor). According to those results, it was possible to specify the optimum behaviour of every
type of foam tested with a certain soil [1].
Tests have been performed on the representative types of soil that includes different geological
conditions in a particular underground construction project [2]. This soil is classified, principally,
according its properties physicals and chemicals. In a general way we can recognize different types
in order to its external shape or grains size.
The effects of the different additives used in tests, in different quantities and under different
environmental and physical conditions are analysed in order to determine the optimum values of
additive concentration. Special consideration is given to the biodegradability of additives and their
potential long-term environmental effects.
The program has established a search criteria based on variation of torque and workability in
transportation. After all lab tests results that have been done, we realised that the decrease of that
parameter implies a significant improvement in TBM-EPB machine (increase the machines speed,
decrease energy consumption).
The program is open to include future testing of new soils, foams and optimization in the analysis,
which can be used in a Web page, which will be updated periodically.
Future research will include further analysis of the data extracted from the tests in order to provide
and compile the information needed to dose soil conditioning additives in the most efficient and
green way. This could become the foundation of a future European Standard for soil conditioning
in TBM-EPB operations.
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3. Framework of the program: FDC (Foam Dosage Calculation) OSCAR

FDC OSCAR software is a tool to query the database created with the results of tests to OSCAR.
This is the version of the user, who can know about the best conditions of use of additives.
To assure that results are adequate and coherent, Figure 2 shows the way to store all data obtained
during the Laboratory tests. When the search motor is activated (see next items to know the
procedure), the program chooses the suitable foams dosage necessary for the sample studied.
Figure 2 :
Example of Laboratory Test
The way to introduce all these data during the Laboratory tests is simple. There are three different
zones:
1. The upper zone of Figure 2, where the particular information tests are stored by the chief
laboratory that introduces simple data (as its own identification, the date, tests time
start) and particular characteristics of the sample (type, quantity, additive,
concentration). With all the information given, the program generates automatically a
code that identifies this particular test.
2. The left zone corresponds to rheological (auxiliary) tests that have been done by the chief
laboratory like the slump, adhesion and baroid tests. It is important to note if there is foam
or not, the mix time in reactor and results of different tests done.
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3. The right zone, which corresponds to reactors results. All these values (mix time, velocity,
pressure, frequency, power, torque) are generated automatically by the reactor.
The FDC OSCAR program structure is divided in four main parts which are listed below:
Initial Menu: The first screen that users see is a presentation of this deliverable (number,
title) and development of this software within the project TUNCONSTRUCT. See Figure 3.
Figure 3 :
D2.5.2.7.pdf
Initial menu.
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Input Data: The user selects a set of parameters in accordance with the conditions of the
work. The parameters used to start the search for better conditions in the database. See
Figure 4.
Figure 4 :
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Input data.
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Dosage Database: The program performs a search in the database and removed as a result
the optimum conditions for the use of the additive. See Figure 5.
Figure 5 :
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Dosage Database.
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Report results: The program gives the option to print the report for the consultation. It
includes data provided by the user as the work, client name, date and other information
about your search. See Figure 6.
Figure 6 :
Preview Report.
The validation of the program is based on tests carried out with the 5 types of soils (> 500 test) and
the creation of a database summarizing the different soils, different pressures, all 3 types of foam
and auxiliary properties.
As all the prototypes of a program (Beta version), the instrumentation of the "FDC OSCAR" will
be updating the different tested soils so their results will be added to the database regularly, so that
the program will be alive, updating and generating the final data in successive versions.
In Chapter 4 of this deliverable has been created a User Manual. It discusses the various elements
that are part of the program and an explanation of the use of the same.
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3.1
Foam design rules
The foam is a mixture of air and an aqueous solution containing the different additives necessary
for the treatment of the ground. See Figure 7.
Figure 7 :
Foam generation.
The main demand of foam as conditioning additive is to create a pasty soil, to build up and to
maintain the necessary support pressure in the working chamber and to prevent high pressure
variations. The created small bubbles (Foam) in the earth past have got the same effect as the
bentonite mud in Slurry machines. The foam is also used to obtain the suitable rheology of the soil.
Some of the main effects, properties, and advantages of the foam addition are listed below:
Improving overall soil behaviour and management.

Improved biodegradability and environmentally friendly effect
Facilitates the extraction of drilling mud
Reduces permeability and improves sealing on tunnel face
Provides plastic properties to soil, generating a uniform and controlled supporting pressure
and a higher stability to the tunnel face
Internal friction decrease
Sticky effect reduction
No dust generation
Parameters related to the creation of foams can be varied in tests to OSCAR. In this way we
generate the foam in different ways by changing:
Volume aqueous solution.

Polymers and foam agents.
Volume of air.
Foam has to be used under defined conditions on site which are fixed by the use of specific
parameters. In the laboratory has studied the influence of each parameter. The three important
foam parameters on the TBM are:
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Cf: Foam additive concentration: 0.5%, 1%, and 2%.
Cf =
Volume _ foam _ surfactant

100
Volume _ foam _ solution
F.I.R.: Foam Injection Ratio. 9.72%, 16.2%, 22.7%
FIR =
Volume _ of _ foam
100
Volume _ of _ soil
F.E.R.: Foam Expansion Ratio 8%.
FER =
Volume _ of _ foam
100
Volume _ of _ solution
These data are part of the database. It is a part of the information the program provides user,
particularly the optimal dosage of foam.
When we do the test with OSCAR, we prepared the different solutions (volume and Cf). The
dosing is done automatically for passing a given volume of air whose value is recorded. See Figure
8.
Figure 8 :
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Foam circuit
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The foam generated is introduced into the reactor. Is mixed with soil type selected saturated and
after a time of mixed start to re-measure all the parameters of the test.
3.2
Specifications of foams
One of the parameters discussed in the previous paragraph is the type of foam agent. As was
revealed in the deliverable 2.5.2.1 (Soft ground tests & definition of suitable parameters) and
worsened further in the subsequent deliverable 2.5.2.9 (Additive for EPB shields, results of lab
tests), foams used in the tests are:
Sika Foam 101 TBM

Sika Foam 102 TBM
Sika Foam 103 TBM
Each of these foams has particular characteristics that make them suitable for different types of
soil. This will improve the performance of the foams. As each of the types of soil presents some
complications if we take into account the effectiveness of these additives.
Sika Foam 101 TBM
Universal Foam: This is designed for the mechanized extraction of all kind of materials found in
most of TBM-EPB operations. See Table 1.
Property
Sika Foam 101 TBM
Appearance
Density (Kg/l)
pH, 20C
Viscosity (cps)
Water solubility
Colourless liquid
Aprox. 1
7
< 200
Ilimited
Table 1: Sika Foam 101 TBM properties
Sika Foam 102 TBM

Gypsum Soil: The temperatures produced in the EPB chamber can be enough high to enable
dehydration and therefore start the gypsum setting process. This foam takes into account this
situation and is specially designed to efficiently condition these kinds of soils. See Table 2.
Property
Appearance
Density (Kg/l)
pH, 20C
Viscosity (cps)
Water solubility
Sika Foam 102 TBM

Uncoloured liquid
1.05
7
400
Unlimited
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Sika Foam 103 TBM

Clay soil: This kind of soil can easily obstruct the screw conveyor used for the extraction of the
excavated soil and others potential hazards. This foam is normally powered with the addition of
other types of polymers and admixtures. See Table 3.
Property
Sika Foam 103 TBM
Appearance
Density (Kg/l)
pH, 20C
Viscosity (cps)
Water solubility
Coloured liquid
1.05
7
400
Ilimited
3.3
Input required and calculation of Foam parameters
One of the problems that we have met on several occasions in this project is number of parameters
to be controlled in each test. The situation becomes more complicated when we get the data of
these variables over time.
As a result of the change of many parameters, the measured values can be represented in different
ways according to the search criteria. This was reflected in deliverables in the past. In deliverable
2.5.2.9 Additive for EPB shields, results of lab tests gave importance to the values of torque and
in the deliverable 2.5.2.4 (In-situ rules and tests for choice of additives according to the geological
conditions) were important rheological parameters of the paste made out of the soil and foam.
In this case, it has built a master table, which contains all data collected and grouped according to
the fields. See Figure 9, in the Annex.
The program works so that the user selected the fields of consultation, beginning to be limiting the
options until you find a range from which to extract the best option. This means that the greater the
number of parameters set by the user, more approximate data will be displayed.
There are a series of data that are essential for the program to carry out the consultation within the
master table:
Type of soil.
Pressure of work.
It also introduces data to identify the customer and the work in which you use the program. For
example: date, customer name
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3.4
Final results
With the data that the user has entered has been set in motion the search engine. As a search
criterion has been established variation of torque. A decrease in this parameter means:
Less energy consumption.

Minor wear on the different parts of the TBM-EPB machine.
Increased the TBM speed.
The information that is presented to the user is detailed in one of the screens of the program, with
the possibility of being printed.
Results screen shows the optimal foams additive and its concentration according the torque
variation. The program also gives the total quantity of foam that customer will need in his project
as well as FER and FIR data.
Note that for this Lite version, FER (Foam Expansion Ration) is always a constant
As additional data, the program shows the most important tests results that have been done to
determines the optimal foam. We can also see a graphical representation of the values of the
parameters: adhesion angle, slump and torque, before and after adding foam. In this way the user is
done graphically idea of the effect of the foam agent.
The report also contains information provided by the user (customer name, work, date) and
search data entered by the user to do the query (soil and pressure work).
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3.5
Future works
In the current version of the program FDC OSCAR (beta) has highlighted the simplicity that it
should have. This premise has been taken into account in the development and use by the user of
the program. This way we can carry out a series of works to complete the potential of the software.
Future Works are:
Parameters
The tests have been done with certain parameters reflecting general conditions:
FER: 8%.
FIR: 9.72%, 16.2%, 22.7%
Pressure: 1, 2 y 4 bar.
Foams: 101, 102 y 103
Soils: sand, mixed, clay, clay with gypsum, silt.
All these parameters can be varied to know the behaviour of additives. In this way we have a
greater range of possible situations that we can find.
We had to do test with samples of real work and above all real working conditions. This implies
pressures and parameters of creation of the foam different from those set out in project. These new
data add to the database.
Search criteria
As discussed throughout the deliverable, the search criteria used in this first version of the program
is the difference of torque over the soil without use of additives. In other deliverable (D2.5.2.4
In-situ rules and tests for choice of additives according to the geological conditions) identified a
number of parameters to define the ideal paste. These parameters serve as a baseline for search that
runs the program.
For example in Sand soil:
Density: < sample saturated density less 0,2 g/cm3

Slump test: < 12 cm +/- 2 cm
Friction angle: 15 < friction angle < 25
Bleeding: < 5%
Oscar torque resistance: < 5 Nm
OSCAR filter test
A series of tables that reflect the values of the different parameters would be the basis of
consultation software. On this circumstance not only take into account the data of torque, but also a
reflection of the rheological behaviour with different properties.
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Laboratory module
The current software is designed on the end-user. We can also develop a laboratory module. This
module would be able to assist in the planning and development of tests to OSCAR. Some of the
characteristics of this program would be:
Creation of Automatic Identification Codes test

Possibility of establishing priorities in the list of Test
Recording on-line data measured with OSCAR
Export to database FDC OSCAR Lite.
Statistical treatment of data recorded.
Consultation website by the values of the database.
Database
The potential of the functionality of the software is directly dependent on the database query that
uses. In the version of this database contains the tests done to current date. Any increase in the
number of tests and data collected allows a closer approximation of the ideal use of the additive
and as a result improved functionality of the program.
We can perform the tests with OSCAR directly on the sample of the real work. In this way the
results generated by the program are customized to the working conditions of each work. These
real data are also used to increase the database query.
All future work earlier also increases the size and quality of the database. That anything that
improves the query, number of parameters in question or the operation of the software is reflected
in the nucleus of the software: the database.
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4.
Users Manual
The manual describing the correct use of the program has the following structure:
I. INTRODUCTION
II. GETTING STARTED
a. System requirements
b. Running FDC OSCAR tool
III. FDC OSCAR TUTORIAL
a. Data input
b. Data output
Initially, the program was developed as an integrated Microsoft Office Access tool. In order to
make the program easier and dynamic, it can be used in a WEB page that will be updated
periodically improving the data bases. The aim is to have in the future, a larger quantity of tests
that will represent the most types of soils.
It is important to note that this program is a Beta version that is a prototype program, so in the
future it will be improved and increased.
I. INTRODUCTION
Software called FDC OSCAR (Foam Dosage Calculation Optimized Soil Conditioning
Additive Reactor) is created to determine the suitable foams dosage necessary in real working
conditions. The data obtained will lead to energy savings, cost reductions and reduced
environmental impact of Earth Pressure Balance TBM operation.
II. GETTING STARTED
This section provides the first-time user to FDC OSCAR tool, instructions for program installation
and start-up on your computer.
II.a System requirements
To operate FDC OSCAR tool, is necessary the following minimum requirements:
Computer and processor:
Personal computer with an Intel Pentium 233-megahertz (MHz) or

faster processor (Pentium III recommended).
Memory:
128 MB of RAM or greater.
Hard disk:
180 MB of available hard-disk space; optional installation files cache

(recommended) requires an additional 200 MB of available hard-disk
space.
Display:
D2.5.2.7.pdf
Super VGA (800 600) or higher-resolution monitor.

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Operating system:
Microsoft Windows 2000 with Service Pack 3 (SP3), Windows XP, or

later.
Internet connection:
Internet Microsoft Explorer 7 or later. Internet functionality requires

dial-up or broadband Internet access; local or long-distance charges
may apply.
II.b Running FDC OSCAR tool

To load the FDC OSCAR tool, simply click the Internet Explorer bottom and select the WEB
(confidential). After that FDC OSCARs welcome window is showed, as you can see in Figure 10
(Annex).
II.c FDC OSCAR TUTORIAL
In this section we provide a simple tutorial to help you get started using the FDC OSCAR tool. This
easy-to-use tool is capable of calculating the right foams dosage from the soil of TBM-EPB cutter
heads.
Note that we are in this FDC OSCAR version, that is the most basic one, and because of it data
bases are not still completes. In fact, at this moment only the whole sand soil tests have been
finished. As soon as the rest of tests will be finished, and increasing the data bases, this tool will
become more and more useful, as you could see in the future.
II.d Data input
First of all, and after pressing the OSCAR bottom to load the tool (see Figure 10), you will be
asked to enter a project title and a customer name that will appear on exported plots. In this case
we will call the project Highway Mediterranean Sea, and the customer will be Spain
Government. That is showed in Figure 11 (Annex).
Next we have to classify the soil sample we have and select the machines conditions. In this
example we have to select a mixed soil, we are working under 1 (bar) of pressure and finally, we
have an estimated volume excavation of 1,000 (m3). See Figure 12 (Annex).
Once all parameters are selected, we continue clicking the SEARCH bottom. This action will
provide the wanted results.
II.e Data output
When the search motor is activated, FDC OSCAR tool estimates the optimum foams dosage result
for this type of soil and gives some additional information. See Figure 13 (Annex).
The program establishes a search criterion according to variation of torque. It is the most important
parameter that we have borne in mind; a variation of its value implies significant changes in TBMEPB work conditions.
Data that are part of the report are:
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Type of foam
The program selects the type of foam that had given better results according to tests
performed.
Concentration of foam (%)

Among the possibilities that are in the database selects the concentration of foam where
there has been a further decline of torque.
Spending foam (l/m3).

The test is performed with OSCAR always with the same amount of soil (it was developed
in deliverable D2.5.2.3. Mock up construction and validation tests for simulating additives
use in Earth Pressure Balanced Machines). So we know the volume of additive that is
spent by volume of saturated soil to excavate.
Total spending foam (liters).

One of the data provided by the user is the volume of soil to excavate. With the previous
data of spending foam, we know the total amount of additive is spent.
FIR. Foam Injection Ratio (%)

There are three possible values that have been studied in test within the project with
OSCAR. The program selects the best value in accordance with the parameters entered by
the user
FER. Foam Expansion Ration (%).

This property remains constant in the different tests so that its value will remain unchanged
in the various consultations: 8%.
Density (g/cm3)
o Density of saturated soil. This is the value of the density of the soil with water
saturation.
o Density of paste. This is the value of the density of soil saturated with water to
which were added foam agent and the different polymers if its necessary.
Adhesion test. ()
o Angle adherence saturated soil.
This is the angle to the horizontal at which the soil sample with water saturation is
starting to flow-out.
o Angle adherence paste (saturated soil + foam).
This is the angle to the horizontal at which the sample of soil saturated with water
and foam begins to flow-out.
o Difference adhesion angle between saturated soil and paste.
This is the difference between the two previous values. This behaviour of the soil is
produced by the addition of foam.
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o Percentage of angle. (%)

This indicates the percentage of adhesion angle that presents the saturated soil over
the value of paste. This is the increase in the flow-out of the sample with foam.
Slump test (cm)

o Slump test of saturated soil.
This is the value of Slump test with saturated soil.
o Slump test of paste.
This is the value of Slump test with paste.
o Difference slump test between saturated soil and paste.
This is the difference between the two previous values.
o Percentage of Slump test. (%)
This indicates the percentage of slump that presents the saturated soil over the value
of paste. This is the increase in the slump of sample with foam.
Torque (Nm)
o Torque of saturated soil.
This is the average of the measured values of torque during the time corresponding
to the saturated soil.
o Torque of paste.
This is the average of the measured values of torque of saturated soil with foam.
o Difference of torque between saturated soil and paste.
This is the difference of torque between saturated soil and paste when we add foam
to the soil. This is the effect of the foam.
o Percentage of torque. (%)
It is the expression of the percentage difference of torque. This is the decline that
occurs in the torque when we add the foam.
Gypsum Soil: The temperatures produced in the EPB chamber can be enough high to enable
dehydration and therefore start the gypsum setting process. This foam takes into account this
situation and is specially designed to efficiently condition these kinds of soils
Finally, the program allows printing the results obtained you can see that, in screen mode, in
Figure 14 (Annex).
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5. Contribution to the overall objectives of the TC project and quantification

on the expected benefit
This document D2.5.2.7 New software, Calculation of foams dosage, including specifications and
users manual, contributes to the ongoing task T2.5.2 Rules for choosing additives according to
geological and environmental criteria, for defining new additives and for treatment of effluent pH
into of Subproject 2 Innovative technologies.
Its main scope has been the development of a useful and easy-to-use tool able to, referring to stored
databases, estimates the optimal foam dosage to apply in a certain soil.
Regarding the contribution of this work to the overall objectives of TUNCONSTRUCT Project, it
becomes necessary to highlight the importance of this to be used directly on the job-site,
optimizing the tunnelling machines work in terms of final costs.
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6. Conclusion
From the analysis of this Deriverable, the following conclusions can be extracted:
The FDC OSCAR program has been developed and is available as a prototype, which needs
further testing and validation.
The structure of the program complies with the basic criterion of the present deliverable:
difference value of torque before and after adding foam, solving the design of batching
with a simple and easy-to-use tool.
The program engine allows calculating approximately the dosage of foam, taking into
account la pressure, type of soil and factor to generated foam. These calculations are made
according to database recorded with OSCAR test.
The database offers, in a simple and summarized way, all the possible dosages of OSCAR
test and it reflects the conditions used in tunnelling and underground construction.
The present deliverable compiles all the Research activities needed for the design and
construction of the software: definitions and criteria.
In the future works have been defined guidelines for action to increase the functionality of
the program.
All this information will be applied in the last deliverable Proposal of draft standard for soil
conditioning in TBM Earth Pressure Balance operations. The standard draft will contain the
description of new equipments and tests needed to select the additives to be used in regards with
the type of ground and the applied operating pressure ahead of a TBM-EPB.
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7. Further work
Task 2.5.2 is being developed on schedule and with very promising results. The next and last step
of this task will consist on the drafting of a document considering the general rules to be followed
in order to efficiently condition soils when operating a TBM-EPB machine in real working
conditions. These rules will serve as a basis for a future European Standard for Soil Conditioning
in TBM-EPB operations.
The organisation and distribution of work is displayed in the following Gantt diagram:
Month /
Deliverable
D 2.5.2.5
D 2.5.2.7
36 37 38 39 40 41 42 43 44 45 46 47 48
New software development for

calculation of foams dosage
SIKA
Proposal of draft standard
BYTP
SIKA
D2.5.2.7.pdf
August
July
June
May
April
March
February
January
December
2009
November
October
In charge /
Timeline
September
Title
August
2008
Page 25 of 33
8. References
[1]
RIVAS, J.L., SANCHEZ-BLANCO, M. and VIDERA, O., D2.5.2.9: Additive for EPB
shields, results of lab tests, TUNCONSTRUCT, Dec. 2007.
[2]
GGOUT, P., VALLON, F., RIVAS, J.L. and VIDERA, O., D2.5.2.4: In-situ rules and tests
for choice of additives according to the geological conditions, TUNCONSTRUCT, August
2008.
[3]
RIVAS, J.L, D2.4.1.4: Shotcrete simplified mix design rules program, TUNCONSTRUCT,
February 2008.
[4]
GGOUT, P. and RIVAS, J.L., D2.5.2.2: Additive for EPB shields, Mock-up,
TUNCONSTRUCT, June 2006.
[5]
GGOUT, P. and RIVAS, J.L., D2.5.2.3: Mock-up construction and validation tests for
simulating additives use in Earth Pressure Balanced Machines, TUNCONSTRUCT,
February 2008.
[6]
QUEBAUD S., SIBAI M., HENRY J.P., Use of chemical foam for improvements in drilling
by earth pressure balanced shields in granular soils. Tunnelling and Underground Space
Technology, Vol. 13, N 2, pp 173-180, 1998
[7]
MILLIGAN G.W.E. and MARSHALL M., Pipeline resistance in difficult ground

conditions, Pipe Jacking Seminar, Wolfson College, Oxford University, Sept 1998.
[8]
MAIDL, U., M. HERRENKNECHT. And L. ANHEUSER, Mechanised shield tunnelling

Ernst & Son. Berlin, 1996.
[9]
BEZUIJEN A., SCHAMINEE, P.E.L. and J.A. KLEINJAN, Additives testing for EPB
shields, Proc. Of 12th conference on soil mechanics and Geotechnical engineering,
Amsterdam Vol.3, pp 1991-1996, June 1999
[10] BEZUIJEN A., Model experiments using foam, Research report N BF51010, GeoDelft,
Sept 2000.
D2.5.2.7.pdf
Page 26 of 33
Annex
D2.5.2.7.pdf
Page 27 of 33
VALUES OF THE DIFFERENCE OF TORQUE BEFORE AND AFTER ADDING FOAM

Pressure
101
1 bar
2 bar
FIR
FIR
4 bar
FIR
9,72%
16,20%
22,70%
9,72%
16,20%
22,70%
9,72%
16,20%
Foam
102
Foam
102
Foam
102
Foam
102
Foam
102
Foam
102
Foam
102
Foam
102
103
101
103
101
103
101
103
101
103
101
103
101
103
101
22,70%
103
101
Foam
102
103
0,5%
S
O
I
L
G
Y
P
S
U
M
W
I
T
H
Cf
1%
2%
0,5%
T
Y
P
E
O
F
C
L
A
Y
Cf
2%
M
I
X
E
D
0,5%
Cf
S
O
I
L
S
O
I
L
1%
1%
2%
0,5%
S
A
N
D
Cf
1%
2%
0,5%
S
I
L
T
Cf
1%
2%
Figure 9 :
D2.5.2.7.pdf
Master Table.
Page 28 of 33
Figure 10 : Program Welcome Window.
D2.5.2.7.pdf
Page 29 of 33
Figure 11 : Entering titles.
D2.5.2.7.pdf
Page 30 of 33
Figure 12 : Selecting soil and work conditions
D2.5.2.7.pdf
Page 31 of 33
Figure 13 : Optimum foam dosage
D2.5.2.7.pdf
Page 32 of 33
Figure 14 : Printing results
D2.5.2.7.pdf
Page 33 of 33

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D 2.5.2.7 New software. Calculation of foams dosage, including specifications

Start date of project: 1. September, 2005

Lead contractor: SIKA

Revision [version 1.0]

Framework of the program: FDC (Foam Dosage Calculation) OSCAR .............................7

Foam design rules .............................................................................................................12

Users Manual .........................................................................................................................19

5. Contribution to the overall objectives of the TC project and quantification on the

Further work ...........................................................................................................................25

General perspective of OSCAR ..................................................................................5

Example of Laboratory Test .......................................................................................7

Initial menu. ................................................................................................................8

Input data. ...................................................................................................................9

Foam circuit ..............................................................................................................13

Master Table. ............................................................................................................28

Program Welcome Window......................................................................................29

Entering titles. ...........................................................................................................30

Selecting soil and work conditions ...........................................................................31

Optimum foam dosage..............................................................................................32

Printing results ..........................................................................................................33

General perspective of OSCAR

3. Framework of the program: FDC (Foam Dosage Calculation) OSCAR

Example of Laboratory Test

Foam design rules

Improving overall soil behaviour and management.

Volume aqueous solution.

Cf: Foam additive concentration: 0.5%, 1%, and 2%.

Volume _ foam _ surfactant

F.I.R.: Foam Injection Ratio. 9.72%, 16.2%, 22.7%

F.E.R.: Foam Expansion Ratio 8%.

Sika Foam 101 TBM

Sika Foam 101 TBM

Table 1: Sika Foam 101 TBM properties

Sika Foam 102 TBM

Sika Foam 102 TBM

Table 2: Sika Foam 102 TBM properties

Sika Foam 103 TBM

Sika Foam 103 TBM

Table 3: Sika Foam 103 TBM properties

Input required and calculation of Foam parameters

Less energy consumption.

Density: < sample saturated density less 0,2 g/cm3

Creation of Automatic Identification Codes test

Personal computer with an Intel Pentium 233-megahertz (MHz) or

128 MB of RAM or greater.

180 MB of available hard-disk space; optional installation files cache

Super VGA (800 600) or higher-resolution monitor.

Microsoft Windows 2000 with Service Pack 3 (SP3), Windows XP, or

Internet Microsoft Explorer 7 or later. Internet functionality requires

II.b Running FDC OSCAR tool

Concentration of foam (%)

Spending foam (l/m3).

Total spending foam (liters).

FIR. Foam Injection Ratio (%)

FER. Foam Expansion Ration (%).

o Percentage of angle. (%)

Slump test (cm)

5. Contribution to the overall objectives of the TC project and quantification

New software development for

Proposal of draft standard

MILLIGAN G.W.E. and MARSHALL M., Pipeline resistance in difficult ground

MAIDL, U., M. HERRENKNECHT. And L. ANHEUSER, Mechanised shield tunnelling