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Page 1 of 2
Nov 2009
ALERT!
Configuration change from double shield mode to EPB mode took about three weeks to accomplish. At about half way
through the headrace tunnel a massive failure of the face blocked the TBM cutterhead and brought progress to a
standstill. Among the many options available to deal with the difficulty, SELI chose to employ polymer resins and a
three-stage process to secure the heading and resume TBM advance.
Technical data of the Beles headrace TBM
Boring diameter:
8.10m
Cutters:
52 x 17in
11.440kN
Cutterhead speed:
6 rpm
2.100kW
First, the void ahead and above the cutterhead was filled with high expansion polymer resins that support the void to
prevent further material falling. TISfoam DRY K, a high expansion ratio organo-silicate resin, was injected through a
set of appropriately positioned pipes through the TBM cutterhead and at sufficient volume to completely fill the cavity.
Secondly, the crown and face area was consolidated using TIS-sil STAB, a low expansion ratio organo-mineral resin.
TIS-sil STAB has exceptional mechanical resistance and adhesion and was injected again through cutterhead and via
pipes positioned appropriately to consolidate the heap of loose rubble in the face and around the cavity.
Following that a hand-mined heading was advanced out above the shield to remove rocks and free up the cutterhead,
being assured at all times that all ahead is stabilized and made safe.
Fig2. Managing rock falls ahead of the cutterhead and samples of resin void filling and consolidation
The headrace tunnel is part of the Beles II multipurpose project. This is an Engineering Procurement and Construction
contract, that was awarded in 2005 by EEPCo, Ethiopian Electric Power Corporation, to the Italian construction
company, SALINI Costruttori Spa, as a 467 million Engineering Procurement and Construction contract.The project
includes construction of a single stage hydropower plant in the Amhara region, about 150km from the town of Bahir
Dar on the south-western bank of Lake Tana. The hydro-power plant has an installed capacity of 460MW.
http://www.tunneltalk.com/TBM-Recorder-Nov09-SELI-breakthrough-in-Ethiopia.php
21/03/2015
Page 2 of 2
contractual deadline.
The headrace TBM, after its recent breakthrough, is to be dismantled
and the finishing works completed by January 2010. Breakthrough of
the Beles tunnel drives follows completion of the 26km long Gilgel
Gibe II headrace tunnel. Subcontracted again to SELI by Salini
Costruttori and also for the Ethiopian Electric Power Corporation
(EEPCo), the tunnel was bored by two 6.98m double-shield TBMs
advancing from the opposite portals and lined with 25cm thick
hexagonal precast concrete segments.
Work started in mid-2005 and proceeded according to schedule
despite the generally adverse geological conditions until in October
Gibe River and the River Omo. Considering the very adverse
geological conditions - the 40 bar mud pressure encountered in
the major fault, the hot water inflows and the consequent tough working conditions - the Gilgel-Gibe II tunnel is
considered one of the most difficult tunnelling projects ever excavated. SELI is well pleased to have tunnelling on both
projects now complete.
SELI
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