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Abstract
In recent years there has been an increasing demand for tunnelling using Slurry and Earth
Pressure Balance (EPB) Tunnel Boring Machines (TBMs) in urban environments with low
overburden and sensitive structures to underpass. Therefore, there is an increasing need for
reliable and realistic methods for the calculation of the necessary support pressure. For the
Crossrail Contract C310 Thames Tunnel two methods for the determination of the support
pressure were applied and investigated in detail. The primary calculations for the tunnel drive
were conducted according to DIN 4085:2011-05; as well as an approach based on the
assumptions of Anagnostou and Kovári (1994), which was used to modify the limits, give
guidance in exceptional situations and refine face pressure determination in Chalk for
upcoming projects. This paper will give an insight of the experience with the calculated and
applied support pressures during tunnelling in London Chalk and beneath the River Thames.
My name is Ester Sophia Elisabeth Karl and I was born in July 1987. I finished my engineering
degree in June 2012 at the Technical University in Aachen (RWTH), Germany.
In October 2011, I started a six month internship at the Crossrail Contract C310 Thames
Tunnel with Hochtief Solutions and wrote my diploma thesis “Determination of required limits
of tunnel face support pressure for the project C310” at the Institute for Geotechnical
Engineering. In my thesis I analysed the method for the determination of the support pressure
from DIN 4085:2011-05 and conducted comparison calculations based on Anagnostou and
Kovári (1994). In addition, I conducted several sensibility analyses to investigate the limits and
advantages of both approaches. As a fully integrated member of the HMJV C310 technical
team, I developed a “calculation tool” to verify support pressures in exceptional situations that
was successfully applied during problems, TBM interventions and planned standstills.
In September 2012, I started working for Hochtief Consult Infrastructure. Since then I was
involved in projects including Able Marine Park (UK), Ringsted Copenhagen (DK), Forth
Replacement Crossing (UK), SAA GA (NL) and as Design Supervisor for the cross passage
construction at Crossrail C310 Thames Tunnel (UK).
According to the German tradition that every tunnel requires a female name, I took the honour
to christen the first C310 TBM Drive from Plumstead Portal to Woolwich with the name “Ester”.
It was also coincidence that the TBM was named “Sophia”, which is my middle name.
In January 2014 I returned to the UK to work in the HMJV tender team for the Thames Tideway
Tunnel and York Potash Mineral Transport System schemes as Design Coordinator.
After the final breakthrough of the last C310 TBM in May 2014, I took the opportunity to analyse
the support pressures and refine the calculation methods for deep tunnels in Chalk.
This paper summarizes the calculations and the analyses I conducted for my thesis and my
evaluation of the applied face support pressures during tunnelling.
Tunnelling in urban areas is challenging, expensive and can be very restricted in available
space, Health and Safety (H&S) requirements and impact on residents. Sensitive or listed
structures have to be protected and the impact of settlements minimised. The risk of
settlements to overlaying structures and hazards such as blow-outs and collapses which could
be caused by tunnelling, must be minimised and mitigated. The selection of the optimum
tunnelling method plays an important role for the success of the tunnelling works, the cost
efficiency and the programme reliability. Recent projects, for example Channel Tunnel Rail
Link Contract 320, showed that slurry shield tunnelling is very reliable and safe particularly
when tunnelling in the Chalk strata.
On Crossrail Contract C310 Thames Tunnel (Tunnel Drive H), for the expected heterogeneous
ground conditions, including Chalk with low overburden, high ground water level and overlying
sensitive structures, Hochtief Murphy Joint Venture (HMJV) choose two Mix-Shield Tunnel
Boring Machines (TBM) from Herrenknecht with slurry/compressed air support. Due to the
tidal effects of the River Thames and the varying overburden and ground conditions, HMJV
had to adjust the face pressure according to the strata and the current ground water level on
a “real-time” basis.
This paper gives an introduction for the theoretical and practical application of the face support
pressure during tunnelling for the C310 Thames Tunnel.
Figure 2: Crossrail C310 Thames Tunnel – Geotechnical Longitudinal Section [provided by HMJV]
It is an ambitious project, both in technical and geotechnical aspects, due to its location and
difficult geological ground conditions. The two Mix-Shield TBMs “Sophia” and “Mary” with an
outer diameter of 7.12m drove through variable ground conditions below the groundwater level
and arrived on the 1st February and 16th May 2014 at North Woolwich (see Figure 3) with
intermediate breakthroughs at the Woolwich Station Box on the 15th May and 13th August 2013.
The strata encountered between Plumstead Portal and North Woolwich Portal were Made
Ground, Alluvial Layers, River Terrace Deposits, Lambeth Group (Upnor Formation), Thanet
Sand and the Chalk strata, which are typical for East London and southern England.
In summary, “Sophia” and “Mary” constructed 3397 rings in 519 days and reached a peak
advance rate of 156m/week.
Figure 8: Example for regular fluctuation of support pressure and according trigger values
Before the tunnelling commenced, HMJV prepared ring based tables with the calculated face
pressure and trigger values in relation to the design water levels which were integrated into
TPC. The “Daily Plan of Advance of Bored Tunnel” (DPABT) and the Daily Shift Review Group
reviewed the tables on a daily basis. They decided which water levels were applicable and
adjusted the tables where necessary to achieve a safe support pressure.
In addition, the values based on Anagnostou and Kovári (1994) and the “calculation tool” were
used to support additional investigations for any exceptional situations.
In the example in Figure 9, the face support pressure is increased in less than one minute from
1.65 to 2.37 bar, breaching the amber trigger value (and fell afterwards to 1.82 bar). The
advance rate fell from 33 mm/min to 0 mm/min. This was due to a valve in the high pressure
plant being defective and therefore closing. It was changed to continue with the regular
advance. As the feed pipe was still working properly, the discharge pipe was not able to
remove the slurry and a tailback occurred.
Impact on the tail skin
This can lead to a constant drop of the slurry level in the excavation chamber (control system
reacts slower than the slurry flow) resulting in a reduction of the face support pressure until a
counter-reaction is applied and the tail skin is fixed.
The drop started during the construction of ring 1230 (see Figure 10) due to incoming annulus
grout entering into the tail skin. This caused leakage through the tail skin-seals. At this
During all of these events there was no occurrence of cave-ins into the excavation chamber,
significant settlement at the ground surface or blow-outs, despite triggering the limits of the
support pressure.
Figure 12: Example of Automatisation of support pressure in the influence zone of the River Thames
The automatisation was achieved with the air pressure regulation system “SAMSOMATIC”,
which regulates the air cushion behind the submerged wall and the information from the TPC.
The main advantage of the automatisation is the improved implementation of the support
pressure within the green range and less breaches of trigger levels. At the beginning of the
first tunnel drive underneath the River Thames, the support pressure was adjusted manually.
For the second drive the automatisation was in place for the entire drive. This led to 10% less
breaches of the green range limits for the second TBM drive compared to the first drive.
The main part of the tunnelling, especially the deep section
underneath the River Thames which was located completely in
Chalk, was conducted using water instead of slurry as the face
support fluid. Chalk has a diverse behaviour for long term and
short term conditions. The long term behaviour is characterized
by low to medium values for cohesion and friction angles whereas
in short term conditions shows rock like behaviour (see Figure
13). HMJV took advantage of this short term behaviour (which is
applicable for the face support pressure) to conduct part of the
tunnel drives with water instead of slurry leading to benefits in the
STP operations.
In addition, the short term stability of the Chalk enabled
compressed air works with reduced pressure. This offered
significant for H&S benefits for the workers as well as providing
Figure 13: Face Intervention
programme savings and mitigation measure during periods when in Chalk
the TBM got stuck.
After rings 178 and 478 (see Figure 14) the crew carried out compressed air interventions to
confirm the quality of the Chalk at the cross passage locations and to inspect the cutter head.
Unfortunately after finalisation of the compressed air intervention and re-filling of the
excavation chamber with support fluid the TBM could not be moved.
To restart the TBM, several mitigation measures needed to be implemented. A hydraulic
power pack on the tail skin articulation was installed to pull the tail skin centimetre by
Furthermore, the support pressure was reduced to the minimum limit as per the alternative
calculation approach with the “calculation tool” to reduce counter force to have more flexibility
for the thrust force. For example, a reduction of 0.4 bar support pressure gives approx. 2500kN
more thrust force.
Alternative calculations were conducted with the “calculation tool” to determine the lowest
possible value without a face collapse. The results after the investigation led to a possible
reduction of the face pressure by 0.45 bar for the following advance. The face pressure was
reduced, the mitigation measures were applied and the TBM could continue under normal face
pressure and advance rate at ring 483.
To ensure that the TBM did not “stick” after the next interventions, several additional provisions
were implemented, such as bentonite lubrication, tail skin articulation and compressed air work
with reduced pressures.
5. Summary
The evaluation has shown that the applied support pressures
did not lead to any face support failures or notable settlements
during C310 tunnelling. The two step system with the back-up
values for exceptional situations, proved safe and reliable. In
addition, reduced face support pressures have shown that the
arching effect in combination with the short term behaviour of
the Chalk, suggest that for future tunnelling projects in Chalk
reduced support pressures can be applied.
In recent years the development of the calculation methods for
support pressures has been pushed forward with more realistic
approaches to the ground behaviour and other influences on
the tunnel face.
In the coming years more tunnels in Chalk will be constructed,
for example the Thames Tideway Tunnel, Crossrail 2 and High
Figure 15: C310 Tunnel “Ester”
Acknowledgements
The author would like to thank all parties involved in the face pressure analysis and application
including Crossrail, HMJV and Hochtief Consult Infrastructure. Special thanks goes to
Andreas Raedle for his mentoring during my diploma thesis. Also a warm thank you to the
HMJV Tunnelling and Technical Teams for answering all my questions/providing all
information and to Crossrail for their approval of this submission.
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