Rehbock Kathmandu 2011 TBM Workshop

TBM Tunnelling in the Himalayan Region, Kathmandu, Nepal, January 27, 2011
TBM TUNNELLING IN THE HIMALAYAN REGION WORKSHOP KATHMANDU JANUARY 2011
Experiences in Long TBM and Drill & Blast Tunnels under Consideration of Risk Management Issues
presented by: M.Sc. M. Rehbock-Sander Amberg Engineering Ltd., Regensdorf, Switzerland
Introduction
Introduction
Challenges
Here at the Gotthard Basetunnel Logistics via shafts and access tunnels
Introduction
S edrun shaft
P ortal installation field
H ead of shaft
A ccess tunnel V entilation tunnel

P ipeline for pneum atic cem ent conveying Trackbound transport C age for: - carrying persons - excavated m aterial - construction m aterial C ounterw eight C oncrete plant, silos
D epth ~800 m
G otthard Base Tunnel

S outhern drives
Trackbound transport
N orthern drives
Foot of shaft
Introduction
Main Challenges of Long and Deep Tunnels
Tunnel length leeds to long construction time Automation of all procedures, trend to the use of TBM Intermediate points of attack if possible High overburden Investigations Not possible over the entire length Higher remaining risks compared to other projects Logistics Long distances Access shafts and galleries
Gotthard, Ltschberg and Vereina Tunnel, Switzerland and Alborz Tunnel, Iran
D
Basel Schaffhausen Zrich St. Gallen
F
Neuchtel Lausanne Sion Genve Zermatt Bern
Baden Solothurn Luzern
A Vereina
Chur St. Moritz
LBT
Ltschberg Base Tunnel
GBT
Gotthard Base Tunnel
Bellinzona Lugano
Technological Progress TBM versus Drill and Blast
Clear tendency to the use of TBM in longer tunnels On the other hand: In Drill and Blast heading the possibilities to react to changing and difficult ground conditions are much bigger Drill and blast technology has developed and high advance rates are possible
Inrush of Water and Debris (Furka-Tunnel)
Technological Progress
St. Bernadino Road Tunnel
Vereina Tunnel
Technological Progress
Vereina Tunnel, Back-up Installations
Suspended back-up platform
Ltschberg: Back- Up Installations, D&B Heading
Gotthard, 12 km lot: Comparision of construction time

Month
TBM D&B
Contractor I
Contractor II
Contractor III
Contractor IV
Gotthard, 12 km lot: Comparision of costs

Offered Price Lot Faido, GBT 3% 3% 9% 0%
TBM D&B
Contractor I
Contractor II
Contractor III
Contractor IV
Ltschberg Base Tunnel, length 34.6 km
(Source: www.bls.ch)
Ltschberg: Excavation Costs of TBM and D&B

SK I II Drill & Blast ESA1 ESA2 ESA3a III IV ESA3b ESA4a No steel arches V ESA5a CHF/m 2960,3300,5320,5710,10740,7110,16090,ET5a 11520,TBM ETA1a ET2 ET3a ET3b ET4a CHF/m 3600,3880,4710,5340,7310,TBM / Drill&Blast 1,22 1,18 0,89 0,94 0,68 1,03 0,72
Ltschberg: Advance Rates of TBM and D&B

35 30 25 m /d a y 20 15 10 5 0 PA 11 PA 12 PA 14 PA 15 PA 16 PA 18 TBM max. TBM mean D&B max. D&B mean
Minimum and maximum advance rates
1. Alborz Highway Tunnel, Iran
2. Gotthard Basetunnel, Railwaytunnel, Switzerland
Alborz Tunnel, Overview

Tehran Shomal Freeway Total length: 121 km - Faster and safer connection - Reduction of fuel consumption - largest structure: Alborz Tunnel - Length ~6300 m - Crossing the Elbrus Mountains
Alborz Tunnel
Height: 2400 m strong winters
Alborz Tunnel, Overview
Alborz Tunnel, Investigations

Geoelectric survey + surface mapping No drill holes Service tunnel (diameter 5.4 m) = exploratory tunnel for the main tunnels
Alborz Tunnel, Predicted Geology and Hazards

Geology Complex and heterogeneous Fault zones Big gypsum/anhydrite bodies Gypsum with massif karstic features with unknown extend below surface Hazards Loose ground in fault zones Swelling and karst in Gypsum Squeezing in high overburden Unknown water quantity, inrush Gases: CH4 + H2S ... others ...
Alborz Tunnel: Open Gripper TBM

Service Tunnel Open Gripper TBM Short Shield Anchors, steel arches and shotcrete directly behind cutter head
Alborz Tunnel, Exploration during Excavation
Alborz Tunnel, Exploration during Excavation: Seismic Prediction with TSP
Alborz Tunnel, Challenges during Excavation

Ingress of water (up to 1000 l/s)

Gases Methane CH4 > explosive Hydrogen sulphide H2S > toxic and corrosive Carbon monoxide CO > toxic
Bypasses
Excavation arround the TBM shield to the front
- when cutter head or shield are
blocked - when they can not be released from inside or by other measures Where: In crown or side wall ???

Bypasses Blockage of Cutter head or Squeezing rock conditions To free the TBM seven times bypasses had to be excavated mainly manually Quick access to the face due to short shield
Bypass in crown pros and cons

Advantages: - in rather difficult conditions: better, more chance for success - steel frames can use shield as foundation - no upward excavation required, crown support can remain once installed - no interference with grippers, bypass can be maintained together with TBM advance Disadvantages: - for excavation down ahead of cutter head: difficult mucking - eventually failures due to low horizontal stress - more time consuming
Bypass measures ahead of cutter head
Bypass measures ahead of cutter head
Alborz Tunnel, Conclusions

Open Gripper TBM was very flexible in difficult ground conditions Excavation works were successfully completed. The contractor never used a TBM before All described hazards and difficulties were overcome without any major accidents or even fatalities. Average advance rate was almost 6.5 m/d Improvement could have been achieved by better preparation for expected problems in advance in contrast to solving problems on demand
Gotthard Base Tunnel (GBT), Construction Sections
Total length: 57 km Five construction sections Erstfeld, Amsteg, Sedrun, Faido, Bodio Three intermediate points of attack Six heading directions
GBT, Tunnelsystem
Faido multifunction station
150.4 km or 99 %
shafts Sedrun emergency stop station
of access passages, shafts and access tunnel Faido main shaft II shaft I tunnels
Sedrun multifunction station
have already been excavated

emergency stop in tunnel
emergency stop station
single track tube
access tunnel Amsteg

waste air fresh air, escape tube
Gotthard Base Tunnel, TBM and Drill& Blast Sections
Drill and Blast
Range of Geological Risk 1992 and Accuracy of Cost Estimation +/- 25 %
Accuracy of Cost Astimation +/-25%
Investigations
Section Sedrun, Geological Investigation with Inclined Borings from the Surface
Tavetsch Intermediate Massif, Support Type SA4.4
Tavetsch Intermediate Massif, Sedrun Heading in Squeezing Rock Conditions
Rock Support in Squeezing Rock Conditions

AST 4.2
Steel arches after installation Steel arches after deformation
local 70 cm
Acceptable deformation
Profil / Stahlbogen bei Tm 1171
Cross Sections
Excavation: 8.60 8.80 m
Excavation: 9.20 13.08 m
Standard cross section
Squeezing rock conditions (L > 1000 m !)
Development of Deformations in TIM
Steel arches with shotcrete application
Section Sedrun, Northern Tunnels
Full face excavation and installation of flexible steel arches with support placement rig Radial Deformations up to 80 cm Average advance rates of 90 cm/day
Piora Basin, Longitudinal Profile

Piora Basin: Triassic deposit of Dolomite in the Gotthard Massif, inserted between Lucomagno Gneiss and Medelser Granite
Piora Basin, Longitudinal Profile
Exploratory Gallery, Ingress of Water and Sugar Grained Dolomite, 31.03.1996
(Source: GBT, der lngste Tunnel der Welt, Die Zukunft beginnt, Hrsg. R.E. Jeker Werd Verlag Zrich, 2002)
Exploratory Gallery, Ingress of Water
(GBT, der lngste Tunnel der Welt, Die Zukunft beginnt, Hrsg. R.E. Jeker Werd Verlag Zrich, 2002)
Investigation of the Piora Basin

Investigation Drillings at GBT level:
Gotthard - Massif
Sugar-grain Dolomite
Profile parallel to GBT (Az N 346 E)

Piora - Basin Lucomagno - gneiss
Projected
solid Dolomite-Anhydrite of formations Lowest level no water

Lowest level of the granular formation granular water and the formation and the circulation ion water circulat
814.63 Above sea level
SSP
Trias Rti - serie
800.00
Kakirit
Medelsian - granite
Gypsum cap
700.00 a.s.l.
Corandoni - zone
Solid dolomite to dolomite marble
5 km long investigation gallery,

600.00 a.s.l.
ingress of water,
Quarten serie
wash in of TBM during investigation drillings

500.00 a.s.l. 460.00 Above sea level
Gotthard Base Tunnel
Exploration - decision tree
Exploration - decision tree

Systematic exploration - Measure of temperature - Tunnel Seismic prediction - Percussion drilling - Protected with preventer Depending on the results excavation Additional exploration - Borlog scanning - additional percussion drilling - Core drilling - Protected with preventer
Alborz Tunnel, Exploration during Excavation: Seismic Prediction with TSP
Piora Basin
Piora Basin, Preventer
Preventer: Shear Preventer Pipe Ram Roto Pac
Piora Basin, Excavation
Range of Geological Risk 2000 and Accuracy of Cost Estimation +/- 10%
Accuracy of Cost Astimation +/-10%
Gotthard Base Tunnel Remaining Risks

More than 100 fault zones predicted Deformations in TBM sections predicted (yielding support types necessary) Squeezing ground conditions Water inrush Rock burst in D&B an TBM sections Face stability
Gotthard Base Tunnel Remaining Risks countermeasures
Risk management process established Flexible rock support means and additional measures must be possible Investigations ahead of tunnel face necessary Probe drilings, preventer protected TSP Open Gripper TBM was choosen Detailed prediction of intensity of hazards and necessary rock support and counter measures based on the geological prediction Detailed action plans for the existing hazards including all contractual aspects were prepared as auxiliary
Gotthard: Hazard Type and Intensity

N
3'000 m abore sea level 2'500
+
Overburden ca. 2'000 m
2'000 1'500 1'000 500
? ?
?
+
+
? ?
+
? ?
+
?
+
?
+
+
?
+
1908
130
?
?
+
+
131
132
133
?
+
Borel-Zone
Stripe gneiss
Tenelin-Zone Stripe gneiss
[km]
130
62c
131
132
Hazards
Detaching of small blocks Loosening in the roof Wedges in the roof Brittle failures Rock burst Plastic deformations
\folien\amberg\gbt-041e.dwg
Face instability Water

Low intensity Medium intensity High intensity Extreme intensity
Gotthard: Rock Support Type FT5B/V

Tunnel cross section
L1* 14 Rock bolt L = 3.0-4.0 m Bolt's grid 1.5 x 1.5 m
Tunnel longitudinal section

L2*
9.20
~ 20 m Section L1
Section L2
Detail section L1*
Detail section L2*
Rock bolt Wire mesh 10 cm Shotcrete Smal bolt for mesh support Wire mesh 10 cm Shotcrete
Gotthard: Distribution of Rock Support Types

[km] 130 131 132 133
Haza rds
Detaching of small blocks Loosening in the roof Wedges in the roof Brittle failures Rock burst Plastic deformations Face instability Water
Low intensity
Medium intensity
High intensity
Extreme intensity
Support types
Excavation support FT 0 FT 1 FT 2 FT 3A FT 3B FT 4A FT 4B FT 5A FT 5B FT 6A FT 6B FT 7 Cast lining 30 cm 30 cm 30 cm 30 cm 30 cm 30 cm 30 cm 30 cm 30 cm 35 cm 35 cm 35 cm
Increasing supp ort
0%
5-10 %
11-20 %
21-30 %
31-40 %
41-50 %
Auxiliary Measure: Injection Gallery beside Tunnel Axis
F aul
t zon
e Exca v
ation p
lanne d
Alrea d exca y vated
Borin g
s Injec tion g aller y
Auxiliary Measure: Injection Gallery beside Tunnel Axis, Intent: Improvement of Rock Conditions
Auxiliary Measure: Injection Gallery in Tunnel Axis, Intent: Improvement of Rock Conditions
Auxiliary Measure :Crown Gallery, Intent: Improvement of Rock Conditions
Auxiliary Measure: Top Heading, Intent: Supporting Vault
Auxiliary Measure: Access to TBM with Side Gallery
Action Plan Injections
Action Plan Spiles (15 m)
Gotthard:
Sueezing Ground conditions Destroyed Steel Arches
Principle of support in TBM Heading

L1* L2*
ur p
a
Yielding principle Yielding principle Support pressure Support pressure
Deformation Deformation
Resistance Principle Resistance Principle
Vereina Tunnel, Steel Arch Setting
Steel Arches/horizontal Slots in Shotcrete Lining

Gottard Base-Tunnel
TH - Steel Arches, Yielding Support at the Gotthard

Before Deformation
After Deformation
Yielding Elements
Yielding elements before and after loading
TBM Switching by Low-Loading Truck
TBM Assembly East Tube
Increasing diameter: 8.83 m > 9.43 m
Vereina Tunnel, Advance Rates Open TBM

Steel Arch Support, Lot T4b
Die durchschnittliche Vortriebsleistung betrug 15.17 m/AT 800 700 600 500 400 300 200 100 0
M rz 9 6 Nov 96 Nov 95 Au g 9 5 Dez 95 Au g 9 6 Dez 96 Ap r 9 6 Mai 95 Mai 96 Okt 9 5 Fe b 9 6 Se p 9 5 Se p 9 6 Fe b 9 7 Ja n 9 6 Ju n 9 5 Ju n 9 6 Ja n 9 7 M rz 9 7 Okt 9 6 Ju l 9 5 Ju l 9 6
692
m/month Lfm /M onat
S trz one Tm 3'415
Monat month
Yielding Steel Arches
Tunnel Faido, Rock Support Concept

- Rock support measures behind cutter head required - Second possibility only 65 m behind the face
East tube 8-16 rock bolts Steel arches every 100 cm 15 cm shotcrete Mean advance about 6.5 m/day
Hazard Scenarios
TBM clambed in Fault zones
Hazard Scenarios
Rock burst
Hazard Scenarios
Damages of rock support due to deformations of the cross section
Gotthard Basetunnel: Breakthrough of the 57 km long tunnel
Conclusions
Advance rates in Drill and Blast Headings have increased in the last 10 years Still Drill and Blast gives more flexibility in difficult ground conditions Open gripper TBM have successfully been used also in squeezing ground conditions High demand of experienced staff for open gripper TBM (interpretation of geology, define necessary rock support, shotcreteing, logistics) All pieces within the puzzle of geology, TBM, logistics, have to fit
Conclusions
Detailed investigations over the entire tunnel length are impossible Concentration of investigations on major risks is necessary Risk management process During excavation additional investigations from the tunnel face are necessary Flexible Heading equipment is required Detailed preparation of counter measures for possible hazards Fair contract and Risk allocation
Thank you very much for your kind attention!

Rehbock Kathmandu 2011 TBM Workshop

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TBM Tunnelling in the Himalayan Region, Kathmandu, Nepal, January 27, 2011

TBM TUNNELLING IN THE HIMALAYAN REGION WORKSHOP KATHMANDU JANUARY 2011

presented by: M.Sc. M. Rehbock-Sander Amberg Engineering Ltd., Regensdorf, Switzerland

P ortal installation field

A ccess tunnel V entilation tunnel

G otthard Base Tunnel

Baden Solothurn Luzern

Technological Progress TBM versus Drill and Blast

Inrush of Water and Debris (Furka-Tunnel)

St. Bernadino Road Tunnel

Vereina Tunnel, Back-up Installations

Suspended back-up platform

Ltschberg: Back- Up Installations, D&B Heading

Gotthard, 12 km lot: Comparision of construction time

Gotthard, 12 km lot: Comparision of costs

Ltschberg Base Tunnel, length 34.6 km

Ltschberg: Excavation Costs of TBM and D&B

Ltschberg: Advance Rates of TBM and D&B

Minimum and maximum advance rates

1. Alborz Highway Tunnel, Iran

2. Gotthard Basetunnel, Railwaytunnel, Switzerland

Alborz Tunnel, Overview

Alborz Tunnel, Overview

Alborz Tunnel, Investigations

Alborz Tunnel, Predicted Geology and Hazards

Alborz Tunnel: Open Gripper TBM

Alborz Tunnel, Exploration during Excavation

Alborz Tunnel, Exploration during Excavation: Seismic Prediction with TSP

Alborz Tunnel, Challenges during Excavation

Alborz Tunnel, Challenges during Excavation

Alborz Tunnel, Challenges during Excavation

Bypass in crown pros and cons

Bypass measures ahead of cutter head

Bypass measures ahead of cutter head

Alborz Tunnel, Conclusions

Gotthard Base Tunnel (GBT), Construction Sections

have already been excavated

emergency stop station

single track tube

access tunnel Amsteg

Gotthard Base Tunnel, TBM and Drill& Blast Sections

Drill and Blast

Range of Geological Risk 1992 and Accuracy of Cost Estimation +/- 25 %

Accuracy of Cost Astimation +/-25%

Tavetsch Intermediate Massif, Support Type SA4.4

Tavetsch Intermediate Massif, Sedrun Heading in Squeezing Rock Conditions

Rock Support in Squeezing Rock Conditions

Steel arches after installation Steel arches after deformation

Profil / Stahlbogen bei Tm 1171

Excavation: 8.60 8.80 m

Excavation: 9.20 13.08 m

Standard cross section

Squeezing rock conditions (L > 1000 m !)

Development of Deformations in TIM

Steel arches with shotcrete application

Section Sedrun, Northern Tunnels

Piora Basin, Longitudinal Profile

Piora Basin, Longitudinal Profile

Exploratory Gallery, Ingress of Water and Sugar Grained Dolomite, 31.03.1996

Exploratory Gallery, Ingress of Water

Investigation of the Piora Basin

Profile parallel to GBT (Az N 346 E)

solid Dolomite-Anhydrite of formations Lowest level no water