Tunnelling with Slurry TBMs Mixshields'

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Tunnelling with Slurry TBMs (Mixshields).
Dr.-Ing. Karin Bäppler, Herrenknecht AG,
Germany. Tunneling Seminar, University of Texas
at Austin, February 21, 2007.
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Outline of lecture.Tunnelling with Slurry TBMs
(Mixshields).

• Introduction Herrenknecht AG
• Required geotechnical information for selection
  of TBM type
• Function principle of Mixshields
• General aspects of segmental tunnel linings
• Thrust rams
• Annular gap and annular gap grouting
• Support pressure
• Bentonite technology/ creation of a filter cake
• Separation technology
• Project examples State of the art of Mixshield
  technology.

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Herrenknecht AG in Schwanau, Germany.
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The global network.
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We offer the complete range in mechanical
Tunnelling.

• For all Demands and every Geology.
• For all Media and Traffic systems.
• All Sizes and Technologies.
• All Services as a Full Service Provider.

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Range of products.
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Geotechnics.Influence of geology and
hydrogeology.
Geology or hydrogeology affect the way and
extent of

• de-watering works
• water permeability
• soil conditioning
• tunnel face support
• support medium, increase of thrust forces
• handling of boulders
• overburden, settlement heave
• tunnel alignment, gradient
• soil bearing capacity, soil stabilization
• soil disposal

Selection of machine and operation principle
Success of project
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Selection of TBM type to be used in soft
ground.Required information.

• Grain size distribution curve
• Wet density ?
• Angle of internal friction ?
• Cohesion c, undrained cohesion cu
• Permeability k
• Groundwater conditions
• Clay mineralogy
• Atterberg Limits plastic limit, liquid limit,
  natural water content (consitency and plasticity
  indexes)
• Quartz content
• Modulus of elasticity Ec
• Earth pressure coefficient K0
• Possible existence of boulders rock type,
  expected amount, expected sizes, UCS, quartz
  content, CAI

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Selection of TBM type to be used in hard
rock.Required information.

• Unconfined Compression Strength (UCS)
• Tensile Strength (Brazilian Test)
• Rock quality (fault zones, weathering grade, )
• Mineralogy (Quartz content, swelling behaviour)
• Cerchar Index (CAI, wear behaviour)
• RQD (Rock Quality Designation)
• DRI (Drilling Rate Index)
• BWI (Bit Wear Index)
• Maximum expected water inflows
• Permeability of the rock
• Maximum expected groundwater pressure

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EPB / Mixshield Range.
Sieve Size
Gravel
Silt
Sand
Fine
Clay
Medium
Medium
Coarse
Fine
Coarse
Fine
Medium
Coarse
Portion of grains lt d in of the total amount
Sieve residue in weight
Grain diameter d (mm)
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Mixshields. Safe Tunnelling in varying Ground.
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General layout Mixshield.

• 1. Submerged wall
• 2. Working chamber
• 3. Air cushion
• 4. Pressure bulkhead

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1
4
2
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General aspects of segmental concrete tunnel
lining.
A precast concrete lining for a TBM- driven
tunnel generally comprises a sequence of rings
placed side-by-side. One ring is divided into
sectors so called segments.
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Installation of segments by the segment erector.
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Segmental tunnel lining.
longitudinal joint
bolt pocket
ring joint
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Shielded TBMs.Thrust rams.
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Shielded TBMs.Thrust rams.
Technical data of reference projects
Calculation of the thrust force
FVTP Thrust forcePbar Pressure thrust
ramsDPiston Diameter pistonnVTP Number of
thrust rams
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Shielded TBMs.Thrust rams.
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Shielded TBMs.Thrust rams.
Example Segment design 61
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Grouting of the annular gap through the tailskin
is todays state of the art.
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Grouting of the annular gap through injection
lines incorporated in the tailskin.
Injection lines
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Dimensions of annular gap.

• Are determined by
• The thickness of the shield shell.
• The height of the shield tail seal.
• The support construction of the shield tail
  seal.
• The conical form of the shield.
• The ground displacement in curves.
• The overcut.

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Purpose of annular gap back-filling.
Filing of the annular gap between the outer
lining surface and the tunnel wall serves the
following functions

• In the short term
• Ensures effective bedding of the lining
  against the enclosing ground.
• Minimizes surrounding ground deformations
  which can cause settlements both above and
  below ground.

• In the long term
• Ensures the most uniform bedding between
  the lining and the ground.
• In certain special cases it provides an
  additional seal.

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Shield tail seal.
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General Layout Mixshield.Support pressure.
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Accurate pressure control via air cushion.
3
2
Reference pressure
pressure (bar)
1
Support pressure control via air cushion
0
0 10 20
30 40 50

time (sec)
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Bentonite technology.Creation of a filter cake.

• Fine grained soil

• Coarse grained soil

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Mixshield.Creation of a filter cake.

• Thickness of filter cake
• 4 loose bedding
• 5 medium dense bedding
• 6 loose bedding

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Hydroshield / Mixshield.Filter cake.
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Separation technology.Scheme.
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Separation technology.Procedure steps.

• Typical procedure steps with separation plants
• Coarse separation with sieve classification gt 2
  mm.
• Desanding at approx. 60 µm with hydrocyclone and
  dewatering sieve.
• Deslurrying at 20 - 30 µm with hydrocyclone and
  dewatering sieve.
• Separation of fines with centrifuge or filter
  press.

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Separation technology.Separation steps.
Sticky soil
Silt
Fine sand
Medium grained sand
Coarse sand
Gravel
Preliminary sieve
1. Hydrocyclone-Stage Dewatering sieve
2. Hydrocyclone-Stage Dewatering sieve
centrifuge/filtration
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Separation technology.Hydrocyclone.
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Separation technology.Dewatering sieves.
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Separation technology.Dewatering sieves.
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Separation technology.Chamber filter presses.
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Required information for the design of a
separation plant.

• TBM diameter
• Average and maximum TBM advance speed
• Total quantity m³/h
• Grain size distribution curve up to 2 µm
• Maximum grain size
• Information about the geology
• Possibilities for disposal of excavated material
• Requirement of customer (e.g. space requirement,
  sound proofing,).

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Separation technology.Stationary separation
plant - CSO Portland.
Compact design 2 Lines with each 800 m³/h Total
power 1.600 m³/h
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Real performed operational pressure during
excavation.
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Hamburg, Germany.4th Elbe River Tunnel.

• Diameter 14,200 mm
• Cutterhead power 3,400 kW
• Tunnel length 2,560 m
• Geology Gravel, silt, sand, boulders
• Contractor - Bilfinger Berger AG
• - Dyckerhoff Widman AG
• - Heitkamp GmbH
• - HOCHTIEF AG
• - Philipp Holzmann AG - Wayss Freytag
  AG
• - Ed. Züblin AG

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Connection to the existing tunnel tubes.
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Demanding Geology under the Elbe River.
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Mixshield Trude.
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Ground stabilization Mixshield Trude.
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One of the largest Mixshields world-wide.

• Shield diameter 14.20 m.
• Length including trailers 60 m.
• 17 hydraulic motors 3,500 kW.
• Max. torque 26 MNm.
• Total weight Mixshield 2,600 t.
• Weight cutting wheel 400 t.

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Center Cutter Wheel.
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Better tunnelling performance with the active
center cutter.
158
100

• Without the center cutter
• With the center cutter

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Jaw Crusher. Capable of handling boulders up to
Ø1,200 mm.

• Crusher jaws can apply force 900 kN.
• Replaceable jaws.
• Crusher grill size 200 mm.

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Replaceable Jaws. Capable of handling boulders up
to Ø1,200 mm.
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Erector (telescopic rotating frame).

• Providing rotation of
• /- 210 degrees.
• 18 to 20 tons segments are
• held using 3 automated
• vacuum plates.
• Segments
• Segment division 621
• OD 13,750 mm
• ID 12,350 mm
• Thickness 700 mm
• Length 2,000 mm

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Main control cabin.
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Slurry Circuit, DN 500. Maximum flow rate of
2,400 m3/hour.
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One of the major technical innovations. Cutting
Tool Change under atmospheric pressure.

• Access to the main arm of the
• cutting wheel under atmospheric
• pressure.
• Operator undertakes maintenance
• procedures without the risk of
• having to work at the tunnel face.
• Back loading cutting tools.

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Procedure Cutting Tool Change.

• Each disc cutter is mounted in a pressurized
  housing with a hydraulically operated
• gate valve.
• Removing of mounting bolts.
• Withdrawal of disc cutter.
• Closing of gate valve to seal the housing off
  from the face.
• Disc cutter removal with a crane attachment.

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Seismic surveying system. Sonic Soft Ground
Probing System (SSP).
Transmitter 1
Receiver 1
Transmitter 2
Receiver 2
Receiver 3
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SSP System.
TBM Transmitter
Boulder
Receiver
Planar
Discontinuity
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Reflections of discontinuities in the ground.
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Graphical interpretation. Sand lenses in front of
the Mixhsield.
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Reflected image of a grout injection wall.
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Project Timetable.

• February 1994 Tender Issued.
• October 1995 Tender Issued.
• Aug 1996 - Feb 1997 Machine Design and
  Manufacture.
• Feb 1997 - May 1997 Pre-assembly Machine and
  Backup Trailers.
• May 1997 Machine Testing Acceptance at HK
  Schwanau.
• June 1997 Disassembly/Transportation.
• June 1997 - Sept 1997 Site Assembly.
• October 15, 1997 Commencement of Tunnelling.
• March 2000 Tunnelling Complete.
• 2003 Tunnel open to the public.

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The worlds greatest Mixshield on mission
breakthrough in Moscow.

• Diameter 14,200 mm
• Cutterhead power 3,200 kW 315 kW
• Tunnel length 2,222 m
• Geology fine to coarse sand,
• clay, limestone
• (medium strength,
• partially very fissured)
• Contractor AO Corporation Transstroy

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Outstanding. 2,222 m tunnel in only 15 month.
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3rd use for the Silberwaldtunnel in Moscow.

• Diameter 14,200 mm
• Cutterhead power 3,400 kW
• Tunnel length 2 x 1,510 m
• Geology fine to coarse sand,
• clay, limestone
• (medium strength,
• partially very fissured)
• Contractor OAO Mosmetrostroy

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Tunnel Cross Section. Silberwald, Moscow.
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Westerschelde, The Netherlands.
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Tunnel design for a road tunnel.
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Westerschelde, The Netherlands.

• Diameter 11,340 mm
• Tunnel length 2 x 6,600 m
• (with 2 machines)
• Segmental lining
• Geology Sand, clay
• Support pressure up to
• 7.5 bar
• Contractor - Bam Infrabouw B.V.
• - Franki nv
• - Hejmans nv,
• - Philipp Holzmann AG
• - Voormolen Bouw B.V.
• - Wayss Freytag AG

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Geology Westerschelde. Pressures up to 7.5 bar.
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Machine features against clogging behavior.
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Working in up to 7.5 bar pressure.Use of
compressed air is not possible.

• Pressure chamber system for up
• to 12 divers and technicians
• enables divers a long-term stay
• under pressure.

• Transfer Shuttle
• Length 2,500 mm
• Diameter 1,300 mm
• Diver Capacity 4

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Transport shuttle.
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Working in up to 7.5 bar pressure.

• 5 operations under saturation.
• Total time under saturation
• more than 40 days.
• Decompression times with operating pressures up
  to 6.9 bar have been in each case 4 days.
• 6 operations for inspection with mixed gas have
  been realized.
• 1652 hrs under pressure with 546 man-lockings.

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Socatop, Paris Maximum safety with large
diameter tunnel excavation in dense urban areas.
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Socatop. Road Tunnel for the A86.
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Socatop, Paris Risk control with large diameter
tunnel excavations in dense urban areas.

• Tunnel alignment traverses highly sensible
  structures (e.g. Versailles) as well as
  important traffic arterias on surface.
• Different geological soil formations along the
  tunnel alignment.
• Convertible machine principle for the technical
  and economical safe advancement process
• (System EPB / Slurry)
• - Open Mode
• - Compressed Air Mode (Semi EPB)
• - EPB Mode
• - Slurry Mode

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Geology Socatop.
Open Mode
EPB
Slurry
EPB
Slurry
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Socatop-Paris, France.

• Diameter 11,565 mm
• Tunnel length 10,500 m
• Segmental lining
• Geology Sand, lime, clay, marl,
• chalk
• Contractor - Campenon Bernard
• - Jean Lefebvre
• - Dumez GTM
• - Fougerolle
• - Socatop
• - Colas

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Conversion Mixshield mode to EPB mode vice
versa.
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Job site Paris. Tunnel passes under sensitive
area.
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Geology at tunnel face.Limestone.
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Geology and TBM modes.Tunnel sections can be
divided into 3 zones.
Open Mode
EPB Mode
Slurry Mode
Slurry Mode
EPB Mode

• 14 in Chalk, clay and limestone.
• 49 in Limestone, marl and mixed strata.
• 37 in Fontainbleau sands.

Open Mode
EPB
Slurry
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Zurich-Thalwil, Switzerland. Herrenknecht for
the Bahn 2000.
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Zurich-Thalwil.Tunnel cross section.
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Zurich-Thalwil.The tunnel route.
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Longitudinal section Zurich-Thalwil.
Mixshield (Slurry / Hardrock) Lot 2.01
Hardrock Lot 3.01
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Zürich-Thalwil, Lot 3.01, Switzerland.Shielded
Hard Rock TBM.

• Diameter 12,290 mm
• Tunnel length 1 x 6,330 m
• Segmental lining
• Geology Molasse
• Contractor - Locher Cie AG
• - Prader AG
• - Wayss Freytag AG
• - CSC
• - Murer AG
• - J.Scheifele AG
• - Specogna Co.

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Zürich-Thalwil, Lot 2.01, Switzerland.Convertibl
e Mixshield.

• Diameter 12,340 mm
• Tunnel length 1 x 2,620 m
• Segmental lining
• Geology Molasse, Sihl ballast
• Contractor - Zschokke Locher AG
• - Prader AG
• - CSC
• - Murer AG
• - J.Scheifele AG
• - Specogna Co.
• - Wayss Freytag AG

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Principle Conversion Mixshield (Slurry/ TBM).
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Tunnelling in urban area.Measures against
Settlement.

• Pipe screen Meinrad Lienert Platz/ Weststrasse to
  avoid blow outs and settlements.
• Time of construction Oct. 1998 to Nov. 1999.
• Semicircular around the excavation profile 10
  concrete pipes (OD 1.55 m) along the last 130 to
  150 m of the soft ground section.
• The machine is equipped with the according
  accessories to carry out ground stabilization
  measures.

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Ground stabilization measures.
233 m Conventional Tunnelling
Ground stabilization measures
38 km Injection Drill Holes
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Zurich-Thalwil. Tunnelling and breakthrough.
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Breakthrough.
Start advancement 31. March 1999 Breakthrough
07. May 2001
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CSO Tunnel for Portland, Oregon.
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CSO Tunnel Portland, Oregon.Geological Profile.
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S-231, West Side CSO Tunnel Portland, U.S.

• Diameter 5,045 mm
• Cutterhead Power 500 kW
• Tunnel length 4,500 m
• Segmental lining
• Geology Sand, gravel, Alluvium
• Contractor - Impregilo S.p.A.
• - S.A. Healy

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S-232, West Side CSO Tunnel Portland, U.S.

• Diameter 5,140 mm
• Cutterhead Power 330 kW
• Tunnel length 1,000 m
• Segmental lining
• Geology Sand, gravel, Alluvium
• Contractor - Impregilo S.p.A.
• - S.A. Healy

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Two Mixshields for SMART Tunnel project in Kuala
Lumpur, Malaysia.
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An innovative idea.Multi-function tunnel in
Kuala Lumpur.
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Tunnel route SMART, Kuala Lumpur.

• North TBM Drive, S-252
• Tunnel length 5,400 m
• Contractor Wayss Freytag AG

• South TBM Drive, S-253
• Tunnel length 4,050 m
• Contractor MMC-Gamuda JV

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Geological conditions.

• 70 traverses karstic limestone and sections in
  compact and fresh marble.
• 30 traverses quarternary alluvial deposits
  (silty, gravely sand) and mine tailings.
• Road tunnel section is marked red

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Exposed karstic rockhead during tin mining.
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Two giants Ø13.21 m Mixshields S-252/ S-253.
Concentrated power for Kuala Lumpur.

• Tunnel length 5,400 m (WF) 4,059 m
  (MCC-Gamuda)
• Cutterhead power 4,000 kW
• Geology Limestone, sand, marble
• Contractor Wayss Freytag AG, MMC-Gamuda

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Possible drillings for karstic zones. Mixshield
Kuala Lumpur.
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Efficient mining in soft ground.Soft ground
tools with wear detection system.

• Enables actual information about cutting tool
  wear.
• Economical tool change.
• Damage limitation on steel structure.

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First milestone, Kuala Lumpur.Breakthrough.
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City-Tunnel Leipzig, Germany.

• Excav. Diameter 9,010 mm
• Cutterhead Power 880 kW
• Tunnel length 2 x 1,782 m
• Segmental lining
• Geology Sand, silt, gravel, lenses of
  sandstone
• Contractor ARGE Tunnel- und
• Ingenieurbau Leipzig Lot B
  (Dywidag Bau GmbH, Alpine Bau Deutschland
  GmbH, Oevermann GmbH Co. KG, Strabag AG)

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City-Tunnel Leipzig, Germany. Tunnel Route.
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City-Tunnel Leipzig, Germany. Geological
profile.
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City-Tunnel Leipzig. Demands on TBM technology.

• Settlement controlled TBM process with liquid
  supported tunnel face (alternatively EPB-Shield).
• Heterogeneous geological conditions.
• SSP (System for seismic probing ahead which
  allows insights into unknown ahead of the
  cutting wheel).
• Equipment and installations for chamber access
  and tool change procedure under pressurized
  conditions according to the latest state of the
  art.

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Cutting wheel design. Main characteristics.

• Safe tool change from the backside of the cutting
  wheel.
• Tools for both soft and hard rock conditions.
• Intensive wear protection.
• Access to the tunnel face possible through
  openings in the cutting wheel structure.
• Cutting wheel design optimized regarding material
  flow.

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Possibility of Injection Umbrella. 10 injection
openings.
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Installation for ground stabilization measures.
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Warning in case of difficult tunnel face
conditions.

• Controlled Boring Process.
• Online Visualization of the TBM advance.

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Muck Control.
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Shanghai, China Safety with large diameter TBMs,
long tunnel drives, high pressures.
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Changjian under River Tunnels, Shanghai.
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Tunnel cross section. Shanghai/China.
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Up to date largest TBMs world wide2 x
Mixshields - Cutting wheel Ø15.43 m.

• Diameter 15.43 m
• Power 3,500 kW
• Tunnel length 2 x 7,170 m
• Geology Sand, clay and rubble
• Enduser Shanghai Metro Shield
  Machine Equipment and Engineering Co., Ltd.

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Accessible cutting wheel spokes for tool change.
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Torque development EBP / Mix.
Torque kNm
Diameter m
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Current trend of mechanized tunnelling.
11,600 mm
1989 Grauholz, Switzerland Herrenknecht
SLURRY-HARD ROCK
14,140 mm
1991 Tokyo Bay, Japan Mitsubishi
SLURRY
14,280 mm
1997 Elbe Tunnel, Germany Herrenknecht
SLURRY
11,565 mm
1998 Socatop, France Herrenknecht
SLURRY/ EPB
14,870 mm
2001 Grone Hart, Netherlands NFM
SLURRY
2006 Nanjing, China Herrenknecht
14,930 mm
SLURRY
15,000 mm
2005 Madrid M30, Spain Mitsubishi
EPB
15,200 mm
2005 Madrid M30, Spain Herrenknecht
EPB
15,430 mm
2005 Shanghai, China Herrenknecht
SLURRY
?
?
?
NEXT
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Thank you for your attention.