Documente Academic
Documente Profesional
Documente Cultură
Mr Merrie graduated from Sheffield Halam University in 1988 Before long his
education in underground construction was utilised at the Channel Tunnel
project. Leading from this has been 23 years of underground and tunnelling
works mainly using Tunnel Boring Machines from Hard Rock gripper TBMs in
Honk Kong to small diameter Earth Pressure Balance TBMs in UK.
Since 1995 Mr Merrie has providing engineering services to a wide range of
projects mainly in the SE Asia and Sub continent where he has completed
three separate contracts on various metro lines in Singapore. He was the
tunnel manager for Contract MC1B on the Delhi Metro and was in charge of
the first use of EPBs in India.
Subsequent to this was a period of business development in SE Asia which
resulted in the award of two contracts in India, AMEL C1 and Tapovan HRT
which was the first deployment of a Shield TBM for the construction of a
head race tunnel in the Himalayas. In conjunction with the TBM supplier
many innovative development were incorporated to cope with the expected
difficult ground conditions.
Mr Merrie is currently working for the TBM Supplier NFM Technologies using
his practical experience of the region and local ground conditions to develop
and supply TBM suitable for the challenging projects within the SE Asia
region.
INTRODUCTION
Whilst tunnelling has been carried out since biblical times, particularly by
the Romans and Greeks in Europe this has generally been in rock where
the ground was self support both in the medium and long term. However
there was a considerable time before soft ground tunnelling was practically
possible. The first notable case of soft ground tunnel under a river was
the carried out by Marc Isambard Brunel in 1825 for the Thames Tunnel in
London. This was only possible by invention of the Tunnel Shield which
allowed the excavation of the face in a controlled manner ensuring face
stability.
However as the shield advanced being jacked off the newly
build brick lining there was a section of unsupported ground which was the
cause of numerous inrushes, one of which almost claimed the life of
Brunel. At this stage the excavation process was entirely manual; a successful rotating cutterhead would not be seen in the UK until 1874 by
Thomas Beaumont which led to the deployment of the Thomas English
Machine in 1880 on the first Channel Tunnel attempt (commonly mistakenly called the Beaumont Machine), Figure 1
an open shield in that there was no support applied to the excavation face.
Thus should the ground be unstable there was no means of supporting the
face much like in Brunels time and collapses and surface sinkhole would
occur. These Tunnel Boring Machines (TBMs) where therefore limited to
ground which was partly self supporting, commonly above the water table.
Figure 2 First Channel Tunnel Attempt, Photo Taken 1985
It was not until the development of the Slurry TBM in 1964 by J.V Bartlett,
the Hydroshield in 1974 by Wayss and Freytag AG and the Earth Pressure
Balance TBM (commonly referred to as an EPB) in 1963 by Sato Kogyo
that tunnels could be constructed in soft ground with any degree of face
support mitigating the danger to the workforce and the general public.
These two face supporting TBMs or Closed Face TBMs have enabled the
development of numerous projects which before had previously been considered impossible. This is the reason that the early Underground in London was almost entirely North of the River Thames where the impermeable London Clay was prevalent, unlike South which consisted of the
highly permeable Thanet Sands & Gravels Figure 3. Indeed the next deep
underground sections were only carried out in xxxx Victoria Line and Jubilee Line and Extension xxxx & 2000
Settlement caused by
face loss
Settlement caused by
shield void losses
= 2.1%
= 4.2%
= 10.4%
A well operated TBM will have faces losses of 0.5-1.0% which as can be
seen in this example is over excavating by less than 0.5m per excavation.
The consequences of face loss are eventually transferred to the surface
where they will become apparent as surface settlement. As shown in Figure 5
Depth
Explanation
The greater the face volume loss, the greater the
total settlement will become. Settlement volume
does not normally exceed face loss volume
In soft to very soft materials (clays, water bearing sands) almost 100% of the volume loss will
be transferred to the surface.
In stiff grounds
(silty sands) there will be a bridging effect and
the overall settlement may only equal 50-75% of
face loss
At greater depth the settlement profile is much
wider (commonly assumed to be 2 x depth), thus
face loss volume would be spread over a wider
area with the total maximum settlement comparably lower than a shallower tunnel where the
settlement profile is narrower. Compare Figures
xx & xxx
Where
Volume
18mm
9mm
6mm
46mm
23mm
15mm
Adequate
Practice
5%
Poor Practice
91mm
46mm
30mm
This highlights the need for strict control on face volume loss, especially at
shallow depths where poor workmanship can quickly turn into excessive
settlements
To prevent the development of face volume loss the excavation face must
be supported, no or incorrect support pressure will result in settlement.
In principal the pressurized medium in the TBM excavation chamber must
balance out the pressure exerted by the weight of the ground and the
pressure exerted by the height of the water table at that location. Thus
shallower tunnels require a lower support pressure (in general) Figure 6
Surface Level
Water Table
Volume
the water inherent in the slurry is not included in the calculation. This is
further complicated when dirty slurry tanks are used for multiple TBMs.
Again this is not real time and can only proved information after the excavation is completed, after which it may be too late. To this means the
TBM manufactures install flow and density meters on both the slurry feed
and slurry return lines (Figure 7).
A simple computer program automatically compares the weight of the
slurry entering the excavation chamber against the weight of the slurry
and excavated spoil removed from the excavation chamber to the STP and
subtracts one from the other there by giving the total weight extracted in
real time.
Again this can be interfaced with audio visual alarms in the
TBM operators cabin and contractor office.
Figure 7 Density and Flow Meters in Slurry Lines
2.2.3 Instrumentation
Instrumentation is used to observe and record the effects of the tunnelling
on the surface and surface structures and where applicable any existing
sub-surface structures. Table 1 indicates the typical instrumentation
INSTRUMENT TYPE
REAL TIME
COMMENTS
SURFACE
Surface
Points
Settlement
Deep Surface
ment Points
Settle-
No
No
BUILDINGS
Electro Beams
Yes
Tilt Meters
No
3D Monitoring
Yes
Uses
a
robotic
theodolite/EDM
sighting
prisms installed on building
DEEP INSTRUMENTATION
Piezometer
No
Inclinometer
No
Extensometer
No
Table 1
Typical Instrumentation
By combining the information produced by the instrumentation the performance of the TBM in respect of settlement can be monitored. However
Seminar Document- REDECON 2010
Key
Normal Segments
Figure 10 Typical Ring Design
2.4.1 Segments bolts,
The segment bolts serve no structural purpose once the rings are grouted
in place and the ground has relaxed onto the lining. Indeed some clients
allow the removal of bolts after a predetermined period of time allowing
the contractor to reuse the bolts.
The bolts are used to hold the segments together during the erection
process and whilst the primary and secondary grouting is performed, this
holding of the segments together ensures that the gaskets are kept under
the correct compression to ensure the gaskets function correctly in the
long term.
Bolts can be straight or curved (Banana Bolts) and serve the same purpose. Straight bolts tend to be quicker to install whilst curved bolts tend
to give better ring build quality
Straight Bolts
Curved Bolt
To ensure the gasket remains in the correct location it is fitted into a gasket groove this ensures the two faces of gaskets on adjacent segments are
correctly aligned, any misalignment will reduce the effective sealing; however a misalignment tolerance of 5-10mm is normally designed into the
gasket
Gasket installed on
Segments
Cutterhead
Main Bearing
Drive Motors
Thrust Cylinders
Articulation Cylinders
Manlock
Erector
Screw Conveyor (EPB only)
Slurry System (Slurry TBM only)
Grouting System
Guidance System
Of these items the cutterhead is the key component of the TBM and the
correct cutterhead must be selected at the start of the contract, unlike
other TBM components it is very difficult to replace the cutterhead once
excavation has commenced.
The cutterhead is equipped with cutting tools with project in front of the
cutterhead structure and are the means of excavating the ground as the
cutterhead rotates. These cutting tools can be discs cutters (15-19 diameter) or drag bits The design of the cutterhead is dependent on prevailing geology which will affect the cutting tools selected and the opening
Articulation
Cylinders
Manlock
Thrust
Cylinders
Tail Seal
Brushes
Screw
Dis
Cutterhead
Articulation
Joint
Drive Motors
Segment Erector
Screw Conveyor
(EPB Only)
Support methodology
Be
charge must be equal to the amount excavated by the cutterhead and being introduced to the excavation chamber. By balancing the amount introduced to the excavation chamber and the amount withdrawn the TBM
operator can maintain the pressure in the excavation chamber.
Thus if the screw speed is too high then the pressure in the excavation
chamber will drop increasing the change of settlement, if the screw speed
is too low then the pressure in the excavation chamber will increase with
the potential for ground heave and/or blocking the excavation chamber.
3.3.2 Soil Improvement
In line with the increased use of the EPB has been the development of
solid conditioning agents which are injected into the excavation chamber
through ports on the cutterhead. Fig 21. There are various types of conditioning agent for use on an EPB with the main two being Foam and
Polymer, other conditioners are available and could form the basis of a
paper on their own.
Decrease the permeability of the ground by decreasing the water ingress and helping to keep the earth receiving pressure
Decrease the friction between the ground and the steel structure
with significant reduction in the cutterhead torque
Add Foam
Result
Treated Material
Slump
60ml Polymer
Added
Figure 23 Affect of Polymer on Saturated Sand (Mapei)
3.4 SLURRY TBMs
These TBMs can be separated in to two categories, Slurry TBMs and Mixshield TBMs with the term Slurry TBM being used as a coverall for both
systems. The chief difference in these systems can be found at the front
of the shield.
The Slurry TBM has a single pressurized chamber full of
bentonite slurry whilst the Mixshield has an excavation chamber and an air
bubble chamber (Figure 24 & 25), these as typical of the Japanese and
European manufactures respectively. This paper will concentrate on the
Mixshield type slurry TBM.
Main Bearing
Manlock
Thrust
Cylinders
Segment Erector
Tail Seal
Brushes
Screw
Dis
Cutterhead
Drive Motors
Articulation
Cylinders
Articulation
Joint
Slurry Suction
Line
Be
The excavation face is support by the introduction of a fluid into the excavation chamber, commonly bentonite slurry. This slurry is maintained at
a pressure predetermined my the contractor so as to support the face
Cutterhead
Excavation
Chamber full
of slurry
Air Bubble
Chamber
50% slurry, 50%
Compressed Air
Slurry Flow IN
Typical properties for 3 basic ground conditions are set out below in Table
2. Note that these are ball park figures and should form a starting point
after which the exact properties can be based on the prevailing ground
conditions.
Parameters
Apparent
Viscosity
(AV)
Plastic
Viscosity
(PV)
Yield Point
(YP)
Filter Cake
Marsh Cone
Viscosity
Density
pH
Sand
Table 2 Typical
Unit
Cp
Permeable
Soils
m/s
15-40
Semi Permeable
m/s
10-20
Impermeable
Soils
m/s
8-20
Cp
5-20
5-10
5-10
Pa
8-5
5-10
<15
mm
Sec
2-6
40-120
1-5
35.50
1-5
30-50
1.02-1.15
1.02-1.20
1.02-1.20
7-10
7-10
7-10
%
1-5
1-5
1-5
Slurry Properties (AFTES Recommendation 2005)
Cut Point
50mm
5mm
80 microns
25 microns
All Materials
Primary Screens
Primary Hydrocyclones
Secondary Hydrocyclones
Dewatering Screens
Centrifuges
Figure 30 Typical Components of STP (Schauenburg)
The actual layout and capacity of the STP are dependent on the size of the
TBM, the required excavation rates and the geology. Obviously the larger
the TBM or the faster excavation speed will require a larger STP. Critically the geology, or more accurately the clay content, determines the capacity of the centrifuges. The fine clay partials in suspension can only be
fully removed by the centrifuges (clay lumps will be removed by the hydrocyclones), thus the higher the clay content the higher capacity of centrifuges is required.
4 CLOSED FACE TBM SELECTION
The differences between the two closed face TBM together with their basic
modes of operation have been highlighted above, the question remains
which TBM for which project? The narrative above highlights that for effective plug formation in the screw conveyor a soil with high fine content
is preferred. However for the slurry TBM a coarse soil with few fines is
preferred. The chart in Figure 31 shows the respective applicable zones
for both the Slurry and EPB TBM.
serve of the Slurry TBM only and the selection process is therefore not a
clear cut as previously.
5
CONCLUSION
Both types of closed face TBMs provide the means of controlling the potential settlement to acceptable.
The means of preventing settlement are similar in both cases; support
pressure in the excavation chamber provides the exaction face with stability during the tunnelling operations with the simultaneous injection of
grout into the annular gap prevents the excavation profile from deforming
after the shield. IN the long term surface settlement is controlled by the
watertight tunnel lining which prevent localized draw down on the water
table preventing settlement in compressive soils,
This prevention of settlement provides safety to the tunnelling process and
to the general public in the longer term.
Should excessive settlement/sinkholes occur there will be serious implications to both program
and to budget, both to the detriment of the contractor and the client.
Whilst it is the Contractors responsibility to carry out the works to the correct standard, the Client should work closely with the Contractors to ensure the design criteria and methodology are correct.
The reliance on
geotechnical instrumentation should be examined, in many cases excessive settlement and sinkholes can be identified from the TBM data, hours,
even days before the settlement/sinkhole occurs
The choice to use a closed face TBM is fairly simple one; however the
choice of which type of closed face TBM, EPB or Slurry is somewhat more
complex with both types offering advantages, with the ground generally
being the deciding factor.