TUNNEL BORING MACHINES IN DIFFICULT GROUNDS

TURKISH TUNNELLING SOCIETY

A UNIQUE PROJECT UNDER VARIABLE

GEOLOGICAL AND WORKING CONDITIONS: EURASIA TUNNEL
Dipl. Eng. Başar ARIOĞLU Dr. Eng. Burak GÖKÇE Prof. Dr. Eng. Ergin ARIOĞLU
Yapı Merkezi Yapı Merkezi Yapı Merkezi

16 November 2016
Steigenberger Hotel, Maslak - Istanbul, Turkey

1
 CAUTION

¾ This presentation is prepared by:

¾ Prof. Dr. Eng. Ergin ARIOĞLU - Yapı Merkezi R&D Department

¾ Dipl. Eng. Başar ARIOĞLU - Yapı Merkezi İnşaat A.Ş.

¾ Dr. Eng. H. Burak GÖKÇE - Yapı Merkezi R&D Department

¾ In this report the remarks, evaluations made and conclusion drawn, that are under
progress, do not reflect the opinions of Yapı Merkezi Construction and Industry Inc. No
liability for negligence or otherwise can be accepted by Yapı Merkezi.

¾ © 2016 Yapı Merkezi Construction and Industry Inc. All Rights Reserved. Except as
otherwise permitted by Yapı Merkezi Construction and Industry Inc., this publication, or
parts thereof, may not be reproduced in any form, by any method, for any purpose.

¾ http://www.ym.com.tr/

2
CONTENT

¾ Project in Brief

¾ Seismicity

¾ Geology

Marmara Sea
¾ Geotechnics

¾ Tunnel Boring Machine

¾ Advance Rates

¾ Standstills

¾ Excavation Parameters

¾ Conclusions
Trakya Formation
¾ Acknowledgements
Source: ATAŞ (2014)

3
PROJECT IN BRIEF
¾ Model: Build – Operate – Transfer
¾ Total Investment: ~1,3 Billion $
¾ Construction Period: 55 Months
• Road and tunnel structures
¾ Operation Period: ~ 26 Years
¾ Total Project Length: 14.6 km
• Part-1: Europe side (5,4 km)
• Part-2: Bosphorus Crossing (5,4 km)
• Part-3: Asia side (3,8 km)
4
¾ 1st and 2nd bridges (total 7x2 lanes)
• 180.000 (1st) and 220.000 (2nd) crossings
per day
¾ Eurasia Tunnel (2x2 lanes)
• 110.000 crossings per day (both directions)
PROJECT PARTIES

OWNER GUARANTOR
Republic of Turkey Prime Ministry
Ministry of Transportation Undersecretariat of Treasury
General Directorate of Infrastructure Investments
INVESTOR / CONTRACTOR SPECIAL PURPOSE COMPANY
Eurasia Tunnel Operation Const. & Invest. Inc.
Yapı Merkezi Construction Inc.

SK Engineering & Construction Company Ltd. CONSTRUCTION COMPANY (EPC JV)

DESIGNER YMSK Joint Venture
Parsons Brinckerhoff
OPERATOR
INDEPENDENT DESIGN VERIFIER EGIS Tunnel Operation Co.
HNTB Corporation
TBM MANUFACTURER
REINSURANCE & INSURANCE Herrenknecht AG
Munich RE SEGMENT PRODUCER
Zurich RE Yapı Merkezi Prefabrication Inc.

ADVISORS
SUBJECT SPONSORS’ ADVISORS LENDERS’ ADVISORS
TRAFFIC Jacobs Engineering Group Arup Group Ltd..
ENVIRONMENTAL ERM Environmental Resources Mangt. Arup Group Ltd.
& SOCIAL
INSURANCE Marsh Insurance Ltd.
JLT Jardine Lloyd Thompson Group
LEGAL Hergüner Attorney Partnership
Fidan & Fidan Law Firm
Skadden LLP
Clifford Chance LLP
FINANCE UniCredit Group
TAX PricewaterhouseCoopers PricewaterhouseCoopers

5
 PROJECT CHRONOLOGY

IC in effect & Asian

Design TBM at Site
Work Site Hand-over
Pre &
YM R&D
Detailed City Plan Ground-breaking TBM factory TBM Construction Operation
Internal
Feasibility Presentation Approval Ceremony acceptance Launching Completion Completion
Study

,WP ,CP  (GD  &GE /CT  ,WN #WI
      

` (GD  (GD  (GD ,CP  ,WN 5GR  #RT &GE &GE
         

Signing of Finance Financial STP Delivery to site TBM

Tender Initialing of IC Signing of IC
Agreements Close & accomplished Breakthrough
Commencing
Construction

Tender Due Diligence Process Design & Construction Operation

Source: ATAŞ (2016)

6
SUCCESSFUL SUBSEA TUNNELLING UNDER BOSPHORUS: MELEN PROJECT
¾ Contractor: STFA + Mosmetrostoy ve Türk ALKE Sarıyer
Beykoz
¾ Project Cost: ~120 milyon US$
¾ Tunnel Length: 5,5 km
Avrupa
¾ EPB-TBM Diameter: 6,15 m -operated in open mode-
with "0" face pressure Yakası Anadolu
Yakası
¾ Minimum Rock Cover Thickness: 35 m
¾ Maximum Depth TBM Tunnel: 135 m (70m-sea)
Ölçeksiz
¾ Formasyon: Dolayoba/Kartal formation Source: Anagnostou (2010) and Bakır et al. (2011)
¾Clayey limestone, limestone-shale, sandstone, GSI: 45-64 (subsea section), several dykes (andesite/diabase) with 1-70 m thickness
¾ Started in March-2008 and finished in April-2009 (one month earlier than planned)

Alüvyon

SECTION EXCAVATED WITH A TBM (3,4 km) SECTION EXCAVATED BY DRILL&BLAST

Deepest Point of TBM Tunnel Source: Modified from Gerek et al. (2010)

7
MAIN CHANGES OF EURASIA TUNNEL AFTER FIELD INVES.&PRELIMINARY STUDIES
Parameters Tender Documents
Tunnel Diameter (m) 12.5
Tunnel Alignment Depth (m) -88.0
Tunnel Gradient (%) 4.0
Face Support Pressure (bar) 9.0
For both traffic direction:
Toll Place
European side
Based on Marmaray Project
Geotechnical Parameters
(there is a distance about 1.5 km)
Seismic Parameters General Assumptions
TBM Excavation Launch Method Deep shafts at European side
Tunnel with variable-larger cross
Approaching Tunnels at Asian side Constant cross section
sections
¾ Eurasia tunnel Project with actual parameters is an unique Project in the World tunnel literature.
8
Changes
13.2
-106.4
5.0
11.0
Asian-European direction:
Asian side
European-Asian direction:
European side
Detailed desk/field and laboratory
investigations, structucture of sea
bottom markedly changes
Detailed geophjysical studies and
probabilistic earthquake
approaches
Transition box at Asian side
Source: ATAŞ (2011)
SEISMICALLY ACTIVE FAULT SEGMENTS IN THE MARMARA REGION

Eurasia Tunnel

North Anatolian Fault Zone

Major Earthquakes (Ms > 6) Median Recurrence Times of Fault Segments

Fault segment Earthquake Fault Segment Last Earthquake Median Recurrence Time
S7, S8 10/9/1509 (Ms = 7.2) S1 12/11/1999(Ms = 7.3) -
S9 10/5/1556 (Ms = 7.2) S2 17/8/1999 (Ms = 7.8) 140 :± 35 years
S2, S3, S4, S5 25/5/1719 (Ms = 7.4) S3 17/8/1999 (Ms = 7.8) 140 :± 35 years
S4 17/8/1999 (Ms = 7.8) 140 :± 35 years
S6 2/9/1754 (Ms = 6.8)
S5 10/7/1894 (Ms = 7.3) 175 years
S7, S8 22/5/1766 (Ms = 7.1)
S6 2/9/1754 (Ms = 6.8) 210 :± 40 years
S11 5/8/1766 (Ms = 7.4) S7 22/5/1766 (Ms = 7.1) 250 years
S3, S4, S5 10/7/1894 (Ms = 7.3) S8 22/5/1766 (Ms = 7.1) 250 years
S11 9/8/1912 (Ms = 7.3) S9 10/5/1556 (Ms = 7.2) 200 :± 50 years
S1, S2, S3, S4 17/8/1999 (Ms = 7.8) S10 - 200 :± 50 years
Source: Erdik (2004) and Wang et al. (2005) S11 9/8/1912 (Ms = 7.3) 150 years

9
SEISMIC JOINTS
Behav
Behavior
havviorr o
off th
the
hee tu
tunnel
unnne
ell unde
e underr an
u an earthquak
earthquake
e akke
wass des
designed
d essigne
ned d for
f r a mome
moment
m meent
ntt magnitude
m dee of
o
Mw = 7,2 ,25 and
,25 a d d design n off func
ffunctional
ncctional
all and
a
safetyy eva
evaluation
e va
aluation earearthquakes
e arrthqquakes s hhave e bee
been
b eeen
analyzed
ana lyz d ac
lyzed according
cc
cordi
rding to t rreturn
eturn period
periods
riodds of
5000 and d 2.500
. 0 years r s, respectively ly.
ly

Shearr ± 50 mm

Source: Modified from YMSK Joint Venture (2014)

10
TBM TUNNEL GEOLOGY OF EURASIA TUNNEL

™ According to geological/geophysical studies (based on borehole logs and seismic refraction)

¾ Asia Side Full face Trakya Formation with different joint, stiffness
and abrasiveness (sandstone, mudstone, dykes) ≈ 564 m

¾ Asia Mixed face (weak and weathered rock mass and marine sediments) ≈ 112 m

¾ Marine sediments (sandy / clayey soil) ≈ 752 m

LITOLOGY Length
¾ Europe Mixed face ≈ 112 m (Between Ring No: 0 - 1627) (m)
Volcanic Dykes 413
¾ Europe Side Full face Trakya Formation ≈ 1800 m Fault & Crushed Zone 101
Source: Bakır, Aydın (2015)

Source: Yapı Merkezi Visual Design (2014)

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ROCK MASS CHARACTERIZATION IN TRAKYA FORMATION
Range of Block Volume -gravel sized-
¾Geological Strength Index (Cai et al. 2004)
Expected GSI Values

Worsening Joint Conditions

(shaded area)
૛૟Ǥ ૞ ൅ ૡǤ ૠૢ࢒࢔ࡶࢉ ൅ ૙Ǥ ૢ࢒࢔ࢂ࢈
ࡳࡿࡵ ൌ
૚ ൅ ૙Ǥ ૙૚૞૚࢒࢔ࡶࢉ െ ૙Ǥ ૙૛૞૜࢒࢔ࢂ࢈

¾ Block Volume
ࡿଵ ൈ ࡿଶ ൈ ࡿଷ
ࢂ࢈ ൌ ൎ ࡿଷ
‫ࢽ ܖܑܛ‬ଵ ൈ ‫ࢽ ܖܑܛ‬ଶ ൈ ‫ࢽ ܖܑܛ‬ଷ

¾ Joint Condition Factor (Palmstrom, 1995)

ࡶ࢝ ȉ ࡶ࢙ Note: “Jw” stands for large-scale waviness and “Js” Block Volume becomes extremely small size
ࡶࢉ ൌ stands for small-scale smoothness. S1, S2, S3 are
ࡶ࡭ spacings between the individual joints in each set
15
and γ1, γ 2, γ 3 are the angles between the joint sets.

Rock mass structure Joint/Block wall surface

description condition
Rock mass unit Joint Joint spacing Block Volume, Vb Joint condition GSI
Description
sets S (cm) (cm3) factor, Jc
Typical blocky sandstone 3 30-100 2.7x104-106 Rough slightly weathered 1.7 – 4.5 55 - 75
Very blocky sandstone with
3 or 4 10-30 103-2.7x104 Rough slightly weathered 1.7 – 4.5 45 - 65
mudstone/siltstone
Mudstone/siltstone with Smooth, moderately
4 10-30 103-2.7x104 0.67 – 1.7 35 - 55
sandstone layers weathered/altered surface
Tectonically disturbed, folded, Slickenslided variable
>4 3-10 27-1000 0.25 – 0.67 20 - 35
faulted zones weathered surfaces
Disintegrated completely Slickenslided highly weathered
- <3 <27 0.1 – 0.25 < 20
crushed rock: translation surface with clay coatings

12
VARIATION OF UNIAXIAL COMPRESSIVE STRENGTH WITH DEPTH

ഥ = mean value
ࢄ
s = standard deviation
V = coefficient of variation (%),
V=s/ࢄ ഥ x100

Source:
Yapı Merkezi
R&D (2010)

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GENERAL OUTLOOK ON MARINE SEDIMENTS

¾ Properties of marine sediments based on cone penetration test (CPT) and measured shear wave
velocity from P/S logging.

¾ Marine sediments (Holecene aged, 7400 ± 1300) varies from coarse-grained soils (gravels and sand) to fine
grained soils (silts and clays) and change both vertically and laterally as a result of sedimental regime.

¾ The coarse-grained soils (usually silty/clayey fine sand) are dense. The sands own high stiffness under high
confining pressure.

¾ Generally speaking, the marine sediments that are normally to lightly overconsolidated at the tunnel axis
depth and consist of inter-bedded sands, silts and clay. The soils appear to be normally consolidated i.e.
OCR≈1, many design properties (undrained shear strength -cohesion value-, stiffness) enhance with depth.

¾ Undrained shear strength can be approximated as:

ࢉ࢛
ൎ ૙Ǥ ૛૛ ൈ ࢽԢ ൈ ࢠ (σv' = effective vertical pressure; γ'=submerged unit weight; z = depth from sea bottom surface)
࣌࢜ Ԣ
¾ Undrained elastic modulus at 50 % peak deviation stress (E50) can be correlated with cu value

ࡱ૞૙ ൌ ૚ૠǤ ૟૝ ൈ ࢉ࢛ ൅ ૚૚ૢǤ ૝ૡ ሺ‫܉۾ܓ‬ሻ

¾ As for the effective internal friction angle (ɐN) for sandy soils can be estimated from the modified equation
(Kulhawy and Mayne, 1990):

ɐNൌ ૚ૠǤ ૟ ൅ ૚૚ ൈ ‫ ܏ܗܔ‬૜૝Ǥ ૜ ൈ ࢗࢉ ൈ ࢠ૙Ǥ૞ (qc= measured cone tip resistance in MPa; z = depth from sea bottom surface in meters)

¾ Some carbonates due to shell of micro/macro organisms are observed throughout the depth of soils up
to 35% CaCO3 at (mean value 25%) Project site. These carbonates were believed in increase "liquefaction
resistance" of sandy soils during seismic loading owing to their roughness structure and reduce in
abrasion.

14
PREDICTED AND MEASURED EFFECTIVE INTERNAL FRICTION ANGLE

Note: Robertson (2009) was used for predicted values. Xm = mean value, Xk(1) = characteristic
value based on student value method, , Xk(2) = characteristic value based on Schneider's method. Source: Yapı Merkezi R&D Department, 2010©

15
BOREHOLE BH1-5

Source: Yapı Merkezi R&D (2012)

16
 SOME ILLUSTRATIVE EXAMPLES OF BOREHOLES
BHJ-1 BH1-4 BHJ-5

Source: Bakır, Aydın (2015)

BHJ-1 (EUROPE SIDE) BH1-4 BHJ-5 (ASIA SIDE TRANSITION ZONE)
0m 0m 0m
0m Sand 10 m
10 m
10 m Clayey Silty Sand 0m
20 m Sand
10 m Mudstone
20 m
Sandstone 30 m 10 m
20 m
20 m 40 m 0m Clayey Silty Sand 30 m
Mudstone Sandy Clay Silt 20 m
Clayey Silty Sand
30 m 50 m 10 m Sandy Clay Silt 40 m Clayey Silty Sand
30 m Sand 30 m
60 m 20 m Sandy Clay Silt
Diabase
40 m
Sand 50 m
30 m Sand 40 m
40 m 70 m Sandy Clay Silt
Mudstone Clayey Silty Sand Gravel
40 m 60 m Sand
50 m Sandstone 80 m Sandy Clay Silt 50 m Mudstone
50 m Mudstone 50 m 70 m
90 m Sandstone
Mudstone 60 m
60 m 60 m Sandstone
100 m
80 m Sandstone
60 m Diabase 70 m Mudstone 70 m
110 m
Sandstone 90 m

Source: Yapı Merkezi Design and R&D Departments (2010)

17
EXISTENCE OF DYKE ZONES

™ In Trakya Formation, Sandstone/Mudstone layers cut through dykes (andesite and diabase).
Such a geological setting creates a different rock mass medium with variable stiffness.
™ Andesite/Diabase dykes have uniaxial compressive strengths more than 200 MPa.
™ Cherchar Abrasive Index (CAI) is an indication of cutter disc/tools wear rate and in the case
of dykes, this index increases up to 4.5 (extremely abrasive).
™ Pink
k color in geological profile below corresponds to dyke zones faced during excavation.

Source: YMSK Joint Venture (2015)

Asia Side Trakya Europe Side Trakya

Parameter Overall Trakya Formation
Formation Formation
Number of Dyke Zone 6 23 29

Total Dyke Length (m) 28 397 425

Average Dyke Length (m) 5 17 15

Average Dyke Frequency (m) 113 83 90

Note: Longest dyke's length is 120.0 m. Source: YMSK Joint Venture (2015)

18
FACE SUPPORT PRESSURE

"Slurry Pressure: Under the expected conditions, up to 10 bar high slurry pressures
will be necessary for operation in soft ground. This figure is higher than the highest
slurry pressures applied ever worldwide (7 bar) and means "unexplored terrority"
with respect to TBM design and TBM operation."

Quoted from "Istanbul Strait Road Crossing - Expert Panel Opinions on TBM
Type and Operation Report", page 1, 7 September 2009.
by
Prof. Dr. George ANAGNOSTOU
Prof. Dr. Nuh BILGIN
Prof. Dr. Levent OZDEMIR
Prof. Dr. Markus THEWES

19
ESTIMATION OF FACE SUPPORT PRESSURE
¾ Face support pressure -at tunnel axis- based on soil/rock
mechanic principles: 0m

ࡰ ࡰ Marmara
ࡼࢌ ൌ ࡼᇱ࢜ǡ࢓ࢇ࢞ ൅ ࢽᇱ ൈ ഥ ൅ ࢽ࢝ ࡴ࢝ ൅ ࡴ࢕ ൅
ൈࡷ 10 m Sea
૛ ૛
Hydrostatic water pressure 20 m
Horizontal earth pressure
¾ Expected maximum effective vertical load on shield 30 m
-neglecting arching effect-:
ࡼᇱ࢜ǡ࢓ࢇ࢞ ൌ ૛ࡰ ൈ ࢽᇱ ൌ ૛ ൈ ૚૜Ǥ ૠ࢓ ൈ ૚Ǥ ૢ െ ૚Ǥ ૙ ࢚Ȁ࢓૜ ൌ ૛૝Ǥ ૟૟࢚Ȁ࢓૛ 40 m

(Tunnel diameter, D = 13.7 m; submerged unit weight of geomaterial, γ'=0.9t/m3)

50 m
¾ Mean value of lateral earth coefficient at rest and active state
60 m
૚ ࣘᇱ 0 m Sand
ഥൌ
ࡷ ૚ െ ࢙࢏࢔ࣘᇱ ൅ ࢚ࢇ࢔૛ ૝૞ െ ൌ ૙Ǥ ૝૚૟
૛ ૛ Sandy Clay-Silt
ࢇ࢚ ࢘ࢋ࢙࢚
ࢇ࢚ ࢇࢉ࢚࢏࢜ࢋ ࢙࢚ࢇ࢚ࢋ 70 m 10 m
Clayey Silty Sand
ࣘᇱ = Effective internal friction of soil/weak rockmass, 30o -on conservative side- 80 m 20 m
¾ Face support pressure -at tunnel axis-
90 m 30 m
(water depth, Hw=62 m; overburden thickness, H=26 m; unit weight of water, γw=1t/m3)
Mudstone
૚૜Ǥ ૠ ૚૜Ǥ ૠ 100 m 40 m
ࡼࢌ ൌ ૛૝Ǥ ૟૟ ൅ ૙Ǥ ૢ ൈ ൈ ૙Ǥ ૝૚૟ ൅ ૚ ൈ ૟૛ ൅ ૛૟ ൅
૛ ૛
૛
ൎ ૚૙ૠǤ ૠ ࢚Ȁ࢓ ൎ ૚૙Ǥ ૡ‫ܚ܉܊‬ 110 m 50 m

¾ TBM was designed on face support pressure of 12 bar.

20
 DISCUSSIONS ON "SAFE HEAVENS" BY MEANS OF GROUND IMPROVEMENT OR
HPERBARIC OPERATIONS IN SUBSEA TUNNEL
¾ Relationship between face support pressure and cohesion of geomaterial for subsea tunnel
conditions for given critical geometric and working conditions, the following relationship
shown in figure can be set up:
¾ Undrained cohesion value of weak, heavily jointed,
Hw weathered geomaterial can be estimated from the
following semi-empirical equation: σ
cm
Ho
Tunnel ૚ െ ‫࣐ ܖܑܛ‬ ૙Ǥ ૞ ൈ ࡾࡽࡰ ൅ ૚Ǥ ૞ ൈ ࡶ࡯࢕࢔ࢊૡૢ
ࢉ ൌ ૙Ǥ ૞ ൈ ൈ ૙Ǥ ૜૟ ൈ ࣌ࢉ࢏ ൈ ࢋ࢞࢖
D Pf ‫࣐ ܛܗ܋‬ ૜૙

¾ For the rock mass under consideration, internal

friction angle (φ = 15o – 30o), the arithmetic mean
Face Support Pressure, Pf

when ground
If c < com; cohesion
improvement ૚ି‫࣐ ܖܑܛ‬
Hyperbaric
Operation

value corresponding value of can be assumed to be about 0.67,

is applied ‫࣐ ܛܗ܋‬
to no face pressure
i.e open mode then the above equation is approximated as:
૙Ǥ ૞ ൈ ࡾࡽࡰ ൅ ૚Ǥ ૞ ൈ ࡶ࡯࢕࢔ࢊૡૢ
ࢉ ൌ ૙Ǥ ૙૚૛ ൈ ࣌ࢉ࢏ ൈ ࢋ࢞࢖
૜૙
Pf = 3.5 bar with
compressed air ¾ Uniaxial comp. strength of rock mass, ࣌ࢉ࢏ = 2.5 MPa

com Undrained ¾ Rock Quality Designation, ࡾࡽࡰ = 0%

entirely crushed
closed mode cohesion of
rock mass ¾ Joint Condition, ࡶ࡯࢕࢔ࢊૡૢ = 5
Geomaterial, c
21
DISCUSSIONS ON "SAFE HEAVENS" BY MEANS OF GROUND IMPROVEMENT OR
HPERBARIC OPERATIONS IN SUBSEA TUNNEL
¾ Then, for given conditions, the cohesion value can be calculated as:
ૠǤ ૞
ࢉ ൌ ૙Ǥ ૙૚૛ ൈ ૛Ǥ ૞ ൈ ࢋ࢞࢖ ൌ ૙Ǥ ૙૜ૡࡹࡼࢇ ൌ ૜ૡ࢑ࡼࢇ
૜૙
¾ Under extreme condition, say, entirely crushed rock mass due to intense tectonic events:
ࢉൎ૙
¾ To sum up:

¾TBM will work in close mode for the stability of excavation face.

¾To eliminate hyperbaric operations, the long standstill for repair/maintenance of TBM is
needed "safe heavens" by means of ground improvements (deep mix method from sea water
surface, chemical/cementitious injections from inside of TBM, excavation of small diameter of pilot
tunnel from land side, freezing, jet grouting, etc.) can be applied.

¾No example Project for ground improvement is present under very high pressure such as
11 bar -unmanagable pressure-

¾Hyperbaric diving is a preferable solution. Hence, the hyperbaric operations with mixed
gas for short term standstills (inspection) and saturation for long term standstills
(unplanned/planned maintenance + repair works) were adopted in the Project.
Source: Yapı Merkezi R&D (2013)

22
TUNNEL AND TBM

TUNNEL
™ TBM Tunnel Length 3,340 m
™ TBM Tunnel Grade ± 5%

™ Maximum Face Pressure 12 bar

TBM - GENERAL

™ TBM Diameter 13.7 m

™ Length of the TBM 120.0 m
™ Weight of the TBM ~3,300 t
™ Installed Total Power 10,330 kW
™ Nominal Torque 23,289 kNm
™ Thrust Force 247,300 kN
EQUIPMENT

™ Φ2000mm Man Lock 2 units

SPECIAL
TBM –

™ Φ1600mm Center Lock 2 units

™ Material Lock 3 units
™ Shuttle (3200 x 1600 x 1600 mm) 1 unit

™ Number of Total Disc Cutters 35 (double)

CUTTING

™ Diameter of Disc Cutters 19 inch

TOOLS

™ Spacing (gauge / center disc cutters) 100mm/120mm

™ Atmospheric Changeable Cutting Knive 48
™ Hyperbaric Changeable Cutting Knive 144

™ Outer Ring Diameter 13.2 m

SEGMENTS

™ Inner Ring Diameter 12.0 m

™ Ring Arrangement 8+1 keystone
™ Segment Length 2000 mm
™ Segment Thickness 600 mm
™ Weight of a Complete Ring 127 t Mix
ix-
x-Shield
d Slurryy Tunnel
el Boring
g Machine
23
TUNNEL SEGMENTS

™ 15.048 piece 600-mm-

Yapı Merkezi
thick precast segments Producer
Prefabrication
(1.672 rings)
* Outer (13.2 m)
Ring Diameter
* Inner (12.0 m)
™ 27.100 t cement
Segment Length 2m

™ 200 t hyperplasticizer Segment Thickness 0.6 m

* Universal
Ring Arrangement
™ 4.800 t fly ash * 8 + 1 keystone
Segment Weight ~ 15 t
™ 66 ton polypropylene fiber Ring Weight ~ 127 t
ERQ 28-days Comp.
™ 79.468 m³ concrete Strength Limit
50 MPa

™ More than 60.000 QA/QC Average 28-days Comp.

tests Connected by using
30.765 bolts
72 MPa
Strength of Production
ERQ Rapid Chloride
1000 Coulomb
Permeability Limit

™ Only 0.3% of produced Average Rapid Chloride

280 Coulomb
Permeability
segmenst were found to
be deficient due to ERQ Service Life Limit 100 years
existance of cracks with Estimated Minimum
127 years
width more than 0.2 mm. Service Life

24
COMPARISON OF TBM TUNNEL PROJECTS (FACE PRESSURES AND DIAMETERS)

Lake Mead, USA ɐ=7.2 m HIGHEST DESIGN PRESSURE Pf-design = 17.0 bar

Eurasia, TURKEY
ɐ=13.7 m
Hallandsas, SWEDEN ɐ=10.6 m
Pf-design = 12.0 bar
Shanghai Chongming, ɐ=15.4 m
CHINA
Nanjing, CHINA ɐ=14.9 m

Weser, GERMANY ɐ=11.7 m

St Petersburg, RUSSIA ɐ=7.4 m

Tokyo Wan, JAPAN ɐ=14.1 m

Hamburg – Elbe, ɐ=14.2 m TTBM Design

GERMANY
Westerschelde, ɐ=11.3 m Applied
NEDERLAND
0 500 1000 1500 2000 2500
DIAMETER2 X PRESSURE (m2.bar)

¾ Eurasia Tunnel TBM (ɐ = 13.7 m) is leading the investigated group of 10 projects when the
“Diameter2 x Pressure” parameter is considered. Source: Untreated data from Anagnostou
(2014) and Holzhauser et al. (2006)

25
ADVANCE RATES BASED ON VARIOUS UNITS

Statistical Parameters Daily Weekly Monthly

Time 476 days 68 weeks 16 months

Maximum 18.0 m/day 86.7 m/week 316.0 m/month

Minimum 0 0 90.0 m/month

Average 7.0 m/day 49.0 m/week 208.3 m/month

Standard Deviation 5.1 m/day 26.6 m/day 64.4 m/day

Coefficient of variation 72 % 54 % 31 %

Source: Yapı Merkezi R&D Department, 2015©

¾ As expected, the coefficient of variation value i.e. magnitude of variability in advance rate
was obtained highest in daily advance rate.

¾ The ratio of (maximum value / average value) was varying between 1.5 and 2.6.

26
 DAILY ADVANCE RATE & SHIELD DIAMETER

26 Project Name General Geology/ Formation

Upp
Upper
pper Grauholz (1) Sand, Gravel, Debris
24 Limitt
Limit
Lowerr Mülheim (1) Sandstone, Claystone

22 Lİmit Strasbourg (1) Gravel, Sand

Taipei (1) Clay
20 Cairo (1) Sand
Duisburg (1) Limestone, Gravel, Clay
Daily Advance Rate, m/day

18 Heinenoord (1) Sand, Clay

Zurich Glatt (1) Debris,unconsolidated materials
16
Sydney (1) Clay, sand, sandstone

14 Buenos Aires (1) Sand, Gravel, Clay

Formation / Section
tion Ave.
Ave
e. Hamburg (1) Gravel, marn, rock block
12 Trakya Formation (4 days of 6.8 Berlin (1) Sand, clay
Holiday excluded) m/day
İzmir (1) Sand, clay
10 8.6
Transition Zones Madrid (1) Clayey Soil, sand, clay
m/day
Marine Sediments (4 days 9.2 Düsseldorf (1) Fine sand, sandy gravel, stones
8 Holiday & 13 days seismic s m/day
ic joints)
Singapore (1) Sediment, clay
7.0
6 Overall Botlek (1) Clay, coarse sand, gravel
m/day
SMART(2) Carstic limestone, sediment
Overall without Mandatory
7.3
4 Standstills (8 days Holiday &
m/day Lefortovo(3) Sand carrying water, silt,
13 days seismic joints) laminated limestone alternatedkil

Overall without Major Channel Limestone, marn, weak

2 9.1 Tüneli(4) sandstone
Standstills (112 days of major
m/day
standstills that are more 1 day) (1) Values were taken from TKJV TBM Expert Report, 2009.
0 (2) Carter& Burgess, Inc., 2007.
D=13.7m (3) Herrenknecht, Bäppler, 2006.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 (4) Harris, vd., 1996.
Tunnel Diameter, D, m
Source: Yapı Merkezi R&D Department, 2014©

27
COMPARISON OF EURASIA / SHANGAI-I / SHANGAI-II MIXSHIELD TBM PROJECTS

Project Name EURASIA SHANGAI - I SHANGAI - II

Project Country Turkey China China
Trakya & Marine
Geology Sand & Clay Sand and Clay
Sediments
TBM Tunnel Length (m) 3340 7476 7472
TBM Tunnel Type Highway Highway Highway
TBM Manufacturer Herrenknecht Herrenknecht Herrenknecht
TBM Type Mix-Shield Mix-Shield Mix-Shield
TBM Diameter (m) 13.7 15.4 15.4
TBM Cutterhead Power (kW) 4900 3750 3750
Cutterhead Power per Unit Area
33.3 20.2 20.2
(kW/m2)
Number of Weeks 68 88 73
Weekly Advance Rate

Maximum (m) 86.7 (@ marine sediments) 144 140

Minimum (m) 0 0 0
Average (m) 49.0 85.0 88.8
Standard Deviation (m) 26.6 36.3 35.3
Coefficient of Variation (%) 54 43 40

28
COMPARISON OF EURASIA / SHANGAI-I / SHANGAI-II MIXSHIELD TBM PROJECTS

¾ At first glance, weekly advance rate in Shangai-I and Shangai-II TBM Projects are markedly
higher than Eurasia Tunnel.

¾ Taking consideration into magnitude of "face support pressure x cross section area of
cutterhead", one obtains the following figures:

¾ Eurasia Tunnel….…………..120 t/m2 x (π/4) x (13.7 m)2 = 17680 t

¾ Shangai Tunnel…………….. 60 t/m2 x (π/4) x (15.4 m)2 = 11170 t

¾ The horizontal force resulting from face support pressure at Eurasia Tunnel is about 1.58
times higher than Shangai Tunnels.

¾ There is no section with highly fractured rock mass in route of Shangai tunnels. Hence, it is
expected to experience higher penetration rate leading to ultimately higher weekly advance
rate. As for the borability of TBM in Eurasia Tunnel Project, ground is extremely variable
from one point to other point due to different stiffness and jointing degree.

29
FACE SUPPORT PRESSURE & TOTAL THRUST FORCE

required
10.8 bar 239000 kN
(90 % of design capacity) (97 % of design capacity)

eq
ivingg iss re
irr operations
3rd Hyperbaric Maintenance

diving
for "Suction
tion Grid Repair"
Re
at 9.8 bar

aturraation
saturationonnd
e/repair
4th Hyperbaric Maintenance
for "Boulder
er Crusher Repair"

atur
or manintenance ce/
ce
at 8.5 bar

bovve
Above
Abov e4 barr, sa
.5 bar,
4.5
1st Hyperbaric Maintenance

or
for
for "Suction
ction Grid Repair"
Re
at 10.8 bar
2nd Hyperbaric Maintenance
for "Cutterhead
erhead Inspection"
Inspe
at 10.3 bar

Excavation
n Direction

Source: Arioglu et al. 2016©

30
DETAILED OVERVIEW OF STANDSTILLS
Ring Completed Face Support Duration
No
(distance) Tunnel (%) Pressure (bar) (days)
Description of Standstill
Cutterhead repair by compressed air diving (Cutterhead
126
1 7.5 4.2 20 damaged due to failure of disc cutter sensors thereby failure of gauge
(252 m)
cutters. Some buckets replaced, composite plates and pins welded)
195
2 11.7 5.2 9 Disc cutter replacement under athmospheric pressure
(390 m)
270
3 16.2 6.0 9 Disc cutter replacement under athmospheric pressure
(540 m)
430
4 25.7 8.2 6 Asian side seismic joint installation
(860 m)
568
5 34.0 9.0 4 Religious holiday
(1136 m)
587 Cutting tool and brush replacement under athmospheric
6 35.1 9.7 6
(1174 m) pressure
690
7 41.3 10.1 7 European side seismic joint installation
(1380 m)
875
8 52.4 10.8 15 Suction grid repair by saturation diving
(1750 m)
933 Cutterhead inspection by saturation diving (6 cm x 75 cm x
9 55.9 10.5 8
(1866 m) 200 cm metal pieces were taken out from jaw crusher area)
1003 Suction grid repair by saturation diving (Middle section of the
10 60.1 10.1 5
(2006 m) old suction grid was removed and the new one was installed)
1146
11 68.6 8.9 19 Boulder crusher repair by saturation diving
(2292 m)
1499
12 89.8 4.2 4 Religious holiday
(2998 m)
Note that 8 days holiday and 13 days seismic joint installations were
Total Standstills 112 mandatory.
Source: Yapı Merkezi R&D Department, 2016©

31
SUMMARY OF HYPERBARIC WORKS UNDER APPROXIMATELY 11 BAR PRESSURE
¾ Starting from excavation of Ring-870 (1740 m), some
blockage issues in suction line was observed and in
consecutive 5 days daily advance rate is approximately
1.7 m/day due to same issue (5 days period average
cutterhead speed, penetration, total thrust force and torque
values are 1.8 rpm, 6.7 mm/revolution, 162 MN and 6.2 MNm, Technical
Drawing of
respectively). Operational parameters indicate anomally. Grid

¾ Blocked pipes were investigated and larger diameter

rock units were identified. It was thought that reason is
the damaged / deteriorated grid behind the stone crusher.
The grid became non-functional. For this reason,
hyperbaric works were carried out at Ring-875 (1750 m).
Stucked
d Stones Stucked
d Stone (~24 cm)
¾ The summary of condition at Ring-875 is as follows:
¾ Excavated Geological Unit: Trakya Formation (Rock
Quality Designation, RQD < 25 % and very weak highly jointed
rock mass conditions)
¾ Face Pressure: 10.8 bar (90 % of the TBM design pressure)
¾ Depth of TBM Tunnel -bottom of tunnel from sea Damaged
d Grid New
w Grid
level-: ~103.0 m (note that the deepest point was 106.4 m)
¾ Type of Hyperbaric Works: Saturation
¾ Total Standstill Duration of TBM for Hyperbaric
Maintenance: 14 days
Source: Yapı Merkezi R&D Department, 2015© Divers Divers

32
CUTTERHEAD TORQUE

Asia – Trakya Formation Marine Sediments and Transition Zones Europe – Trakya Formation

European Side Seismic Joint

Asian Side Seismic Joint

¾ Average cutterhead torque values in Asia side Trakya formation, marine sediments and Europe side
Trakya formation are 10.0 MNm, 4.5 MNm and 6.0 MNm, respectively.
¾ Torque values were representing a high variation (38 %) in Asia side Trakya formation due to varying
formation characteristics. When the marine sediment excavation started, torque values were decreased
and the variations were decreased to (22 %). Source: Yapı Merkezi R&D Department, 2015©

33
CUTTERHEAD TORQUE AND SPEED

Limit Torque
Cutterhead Torque (MNm)

Nominal Torque

Producer Limit = 3.2 rpm

Trakya Formation

Marine Sediments

Cutterhead Speed (revolution per minute)

Source: Yapı Merkezi R&D Department, 2015©

34
SPECIFIC ENERGY CONSUMPTION

Asia – Trakya Formation Marine Sediments and Transition Zones Europe – Trakya Formation

European Side Seismic Joint

Asian Side Seismic Joint

¾ The lowest cutterhead electricity consumption was observed during excavation of marine sediments with
an average specific energy value of 3.1 kWh/m3. Spent average specific energy in Asia and Europe side
Trakya formation were 15.9 kWh/m3 and 14.3 kWh/m3, respectively.
¾ At some rings, it was observed that the specific energies were jumped due to existance of dyke zones.
Source: Yapı Merkezi R&D Department, 2015©

35
RELATIONSHIP BETWEEN SPECIFIC ENERGY AND PENETRATION

Curve generated from the Eurasia Tunnel data

Curve approximated by Authors based on the

data given in Barla (2000).
(ɐ11.8m; through Dolomite, Limestone and Argillite Formations)

36
RINGBUILD DURATION

Eurasia
Tunnel
(φ13.7 m)

Learning Period

Eurasia Tunnel TBM

¾ Maximum segment weight is 15 t and
complete weight of 8+1 ring is 127 t. Source: Limits by Maidl and Comulada (2011), Eurasia
¾ Segment erector's rated load is 16 t. data by Yapı Merkezi R&D Department, 2015©

37
TBM EXCAVATION PARAMETERS

Asia Asia Marine Europe Europe

Overall
Excavation Parameters Trakya Formation Transition Zone Sediments Transition Zone Trakya Formation
(Rings: 0 - 1670)
(Rings: 0 - 282) (Rings: 283 - 338) (Rings: 339 - 714) (Rings: 715 - 770) (Rings: 771 - 1670)

Excavation Dates 5/5/14 - 6/8/14 7/8/14 - 15/8/14 16/8/14 - 22/11/14 23/11/14 - 9/12/14 10/12/14-23/8/15 5/5/14-23/8/14

Calendar Days 94 9 99 17 257 476

Major Stop Days 38 0 23 0 51 112

Section Length (m) 564 112 752 112 1800 3340

Average Advance Speed (mm/minute) 20.2 28.6 24.4 14.9 13.9 17.8

Average Penetration (mm/revolution) 9.2 10.0 18.4 7.0 5.9 9.4

Average Cutterhead Speed (rev. per minute) 2.2 2.9 1.5 2.2 2.4 2.2

Average Torque (MNm) 9.8 7.6 3.7 7.0 6.0 6.2

Minimum Total Thrust Force (kN) 57,841 94,406 106,920 154,476 21,679 21,679

Maximum Total Thrust Force (kN) 113,240 122,683 238,935 210,517 199,412 238,935

Min. Pressure -TOP- (bar) 0 5,3 6,2 9,4 0 0

Max. Pressure -TOP- (bar) 5.4 6.3 9.6 9.7 9.8 9.8

Specific Energy (kWh/m3) 15.9 10.6 3.4 17.1 14.3 12.1

Average Advance (minutes/ring) (*) 105 71 84 145 146 123

Average Ringbuild (minutes/ring) (**) 62 45 53 51 44 49

Average Downtime (minutes/ring) (***) 105 100 97 129 101 102

(*) Higher advance durations (tadvance > 300 minutes/ring) are excluded.
(**) Higher ringbuild durations (tringbuild > 120 minutes/ring) are excluded.
(***) Major stop durations (tdowntime > 1,000 minutes/ring) are excluded. Source: Yapı Merkezi R&D Department, 2015©

38
REPLACED DISC CUTTERS, SCRAPERS AND BRUSHES

¾ Replacement number of tools by considering formation in Eurasia Tunnel.

Asia Side Transition Zones and Europe Side

Total
Tool Trakya Formation Marine Sediments Trakya Formation
Number
(0 – 564 m) (565 m - 1540) (1541 m – 3340 m)

Disc Cutter 54 69 325 448

Scraper 16 17 52 85

Brush 0 475 0 475

Source: Yapı Merkezi R&D Department, 2015©

¾ Some excavation parameters by considering disc cutter type in Eurasia Tunnel.

Disc Average Excavated Average

Number on Average Tracked
Cutter Linear Tunnel Excavated
Cutterhead Length (km)
Type Distance (m) Volume (m3)

Center 6 1534 834 1445

Face 23 284 984 1126

Gauge 6 97 697 703

Source: Yapı Merkezi R&D Department, 2015©

39
MAJOR CHALLENGES - I
™ Geometric Restrictions:
¾ Tunnel diameter (two-deck road tunnel)

¾ Overburden (minimum 2 times diameter)

¾ Gradients (±5%)

™ Highly Active Seismicity:

¾ Slip rate of about 20-24 mm/year on fault system based on the GPS measurements

¾ Distance to North Anatolian Fault Zone is 16 km

¾ The probability of a Mw ≥ 7.0 earthquake is 35 – 70 % in the next 30 years

¾ First application of seismic joint for subsea tunnel in worldwide

™ Extremely Variable Geology:

¾ Subjected to twice "orogenic events" in history

¾ Trakya formation with volcanic dyke intrusions (5 – 250 MPa)

¾ Transition zones

¾ Faulted and weakness zones

¾ Marine sediments

40
MAJOR CHALLENGES - II
™ Hyperbaric and Operational Conditions:
¾ Risky project since face support pressures were above 4.5 bar for 79% of the alignment with respect of
saturation diving by nitrox/trimix gas mixture
¾ Saturation diving with nitrox/trimix gas mixture where face support pressures are above 4.5 bar
¾ First application of hyperbaric operation under 11 bar in worldwide TBM projects.
¾ 4 times hyperbaric maintenance/repairs
™ Aggressive Medium:
¾ Volcanic dykes of andesite and diabase.
¾ 28 dyke intrusions
¾ Total length of 413 m (12 % of tunnel)
¾ Frequency of about 90 m
¾ Thicknesses between 1 m and 120 m
¾ UCS more than 200 MPa
¾ CAI values are reaching up to 4.5 (“abrasive” and “very abrasive” classes)
™ High Capacity Demands:
¾ Face support pressure of 10.8 bar (90% of capacity)
¾ Thrust force of 239 MN (97% of installed capacity)
¾ Torque of 20 MNm (86% of nominal capacity)
¾ Separation plant usage for 18.0 m/day (90% of capacity which is 2800 m3/day)

41
CONCLUSION
¾ Responses to Challenges
™ Preliminary studies (literature/desk studies and
detailed site/laboratory investigations)
™ Latest Mixshield TBM technology (advanced
monitoring systems, atmospherically changeable cutting
tools, special pressure equipment)
™ Seismic Joints (innovated, designed, localized, tested,
implemented)
™ Continuous monitoring and utilization of gained
knowledge (excavation parameters and downtime root
causes) on upcoming excavation phases
™ Best experts for all aspects of the project
™ Utilizing and developing technology
™ Effective learning (cutting tool replacement duration,
ringbuild duration, interaction between rockmass/soil and
TBM, practical solutions at site)
™ Experienced TBM crew (average 2.8 TBM projects /
personnel and average 15.0 km TBM tunnel / personnel)
Breakthrough: 22/08/2016 - 17:00
™ Collaborative and succesful Project Management Average Daily Advance Rate: 7.0 m/day
and Yapı Merkezi Prefabrication Factory Utilization Ratio: 31%
42
ACKNOWLEDGEMENT

¾ Owner : Ministry of Transportation

General Directorate of Infrastructure Investments (AYGM)

¾ Investor/Contractor : Avrasya Tüneli İşletme, İnşaat ve Yatırım A.Ş. (ATAŞ)

Yapı Merkezi and SK EC Joint Venture (YMSKJV)

¾ Yapı Merkezi : Board Members

¾ Host : Turkish Tunnelling Society

“... the Project will encourage the tunneling

world to attempt deeper, farther and larger ...”
Dr. Ersin ARIOĞLU (2015)
Founder of Yapı Merkezi
43
 We
e wo
w ould
would d li
ike
e to
like o th
haank
thank k you
y
forr your
y r ininterest
nterest in
no our
presentation n...

Source: Arıoğlu, Ersin (2016)

44