Ens 100302 en Fs Tad Lecture 03

Tunnel Engineering
Design and Analysis
COURSE LECTURES
#03 – Tunnel Excavation Methods
Dr Federica Sandrone
EPFL−ENAC−LMR
Outline
1. Drill-and-blast tunnelling in rocks
2. Roadheader and other excavation machines
3. Tunnel boring machine in rocks
4. Shield tunnelling machine in soils
5. Ground improvements during excavation
6. Selection criteria of excavation methods
Tunnel Engineering
Laboratoire de Mécanique des Roches - LMR Design and Analysis
2
1
Conventional underground tunnelling
• Discontinuous excavation process
• Small advance steps
• Full face or partial face
SUPPORTING EXCAVATING
MUCKING
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Continuous mechanized tunnelling
• Continuous excavation
• Mucking of excavated material
• Support installation
EXCAVATING
MUCKING
SUPPORTING
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2
Drill & Blast
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Excavation cycle
Charging
1h
Drilling
1-2 h
Firing
Shotcreting 1h
Ventilation
1-2 h
Bolting
Scaling
1-2 h
Mucking
Tunnel Engineering
1-3 Laboratoire
h de Mécanique des Roches - LMR Design and Analysis
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3
Drilling methods
Penetration rate is a function of geological conditions

Medium to hard rock /
abrasive rock also
102-203 mm diameter
All kinds of rock
All kinds of rock
> 152 mm diameter
54-102 mm diameter
Tricone
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Tunnel blasting
A Cut
B, C Stoping holes B
F
D Contour: Roof & Wall holes
A
E Floor holes (lifters)
C
F Second contour
E
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4
Contour holes: Look-out (L)
Roof, wall and floor holes have to be angled out of the contour (LOOK OUT)
to allow space for the drilling equipment for the coming round keeping the
designed area.
LOOK OUT < 10 cm + 3 cm/hole depth
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Cut
Tunnel blasting: one free surface
Second free surface has to be created (cut)

Empty
holes
60°
V-cut Fan cut

Parallel cut
The rock can break and be thrown away from the surface
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5
Number of holes – Rule of a thumb
• Diameter: 45 mm
• Length: 4 m
• Number = section size (m2) + 35
With larger holes the number decreases slightly
With longer rounds the number increases
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Explosives - Charging
Explosive powders Less used
Explosive gelatines Mainly used as booster or for opening the cut slot
ANFO (Ammonium Nitrate – Fuel Oil) Cheap and quite

widespread but not water
resistant
Emulsions (slurries) Pumpable, water resistant, widespread
The charging of blastholes can be carried out either manually with plastic
pipe charges or mechanically with pneumatic charging equipment
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Charging
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Firing
The ignition system:

• Electric detonators or non-electric detonators (NONEL)
• Detonating cords
• Retards (reducing vibrations & new free surfaces)
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7
Ventilation
After firing: fumes high temperatures & harmful

concentrations of:
• Carbon Monoxide CO
• Carbon Dioxide CO2
• Nitrogen Oxides NOx
• Dust
Ventilation is necessary [Recommendation SIA 196, 1998]
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Scaling
• Remove potentially unstable blocks
• Preparing the rock surface for shotcreting and/or bolting
• Dangerous operation for workers
• Manual, mechanised
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8
Mucking
LOAD
TRANSPORT
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Drill & Blast
ADVANTAGES ☺ DRAWBACKS
No protection or support given to the

Flexibility
rock while scaling
Requires advancing interruption for

Suitable to excavate hard rocks
ventilation and scaling
Possibility of excavating tunnels of

Vibrations and fumes
different sizes and shapes
Low capital investment (short tunnels) Overbreak
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9
Traditional mechanised tunnelling
Digger Impact breaker, ripper, pick, and bucket

Boom Excavator for weak weathered rock and firm soil
Road-header Competent rock
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Digger / Hammer
Hydraulic or pneumatic
• Flexibility (weak rocks)

• Performances comparable with
drill and blast
• No vibrations and fumes
• Dust (water spraying)
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10
Conventional Excavators
• Weak rocks
• Rippers (hard rock inclusions)
• Space (rotation and arm
movements)
• Foundation stability
• No vibrations and fumes
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Road-header
☺ Moderate rock strength (up to 120 MPa)

Cutter-head
Extension arm or Boom
Muck conveyor
Loading apron
Crawler chassis
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11
Road-header
Rotating drum Rotating drum

perpendicular to the boom in line with the boom
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Muck conveyor
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12
Road headers & Excavators

Flexibility rock while excavating. Limited to
stable ground.
Possibility of excavating tunnels of Suitable to excavate rocks of UCS up

different sizes and shapes to 120 MPa
Need to threat dust with sprayed

No vibration and fumes
water
Low capital investment

Stable foundations
No installation time needed
Relatively short time from order to

Space for rotation and movements
delivery at the site
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Tunnel Boring Machines
Reaming Competent rock

Machine
Rock TBM Non-Shield TBM
Gripper TBM Competent rock
Open Face Weak, soft rock Firm soil
Mechanical Weathered, highly Firm soil

Face Support fractured rock
Shield TBM Compressed Rock-soil mixed Firm soil with

Air Shield ground groundwater
Soil TBM Slurry / Rock-soil mixed Loose sandy

Hydro-Shield ground soil
Earth Pressure Rock-soil mixed Soft clay

Balance Shield ground
Double Shield Ground conditions from competent rock

to loose/soft soil
Hybrid Shield
EPB-Slurry Varying ground conditions suitable for
Convertible Shield EPB and slurry machines
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13
Excavating
Big circular section:
• 11 m for rock TBM
• 15 m for shield
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Mucking & Supporting
Ring erection: short time

Continuous mucking from the excavation face
(20-40 minutes per ring)
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14
Reaming Machine
Non-Shield TBM
Rock TBM Gripper TBM
Open Face
Mechanical Face Support
Shield TBM Compressed Air Shield
Soil TBM Slurry / Hydro-Shield
Earth Pressure Balance Shield
Double Shield
Hybrid Shield
EPB-Slurry Convertible Shield
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Tunnel Reaming & Enlarge Machines
Axial pilot tunnel

Cutter head
Gripper (Tractor)
Rear support
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15
Tunnel Bore Extender
Uetliberg Tunnel (Switzerland)
• 5 m pilot tunnel
• 14.4 m final section
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Gripper TBM
Competent and hard rock formation - Homogeneity

Grippers assure the face advancing
Gripper
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Cutting tools
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Gripper TBM
Single gripper TBM
Double gripper TBM
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Gripper TBM

Visual contact with the rock mass rock while excavating. Limited to
stable rock
Suitable to excavate hard rocks of Small flexibility (fault zones, not

UCS up to 300 MPa homogeneous rocks)
Free space for ground probing

equipment (treatment and Dust treatment is needed
investigation)
Minor ground support measures
(shotcrete, rock bolts) if necessary
can be installed very close to the
excavation face
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Gotthard Basis Tunnel (Amsteg)
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Reaming Machine
Non-Shield TBM
Rock TBM Gripper TBM
Open Face
Mechanical Face Support
Shield TBM Compressed Air Shield
Soil TBM Slurry / Hydro-Shield
Double Shield
Hybrid Shield
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Open Face Platform Shield
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Open Face Shield - TBM
Open Face Tunnelling Shield Open Face Shield
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TBM with Mechanical Face Support

Flood doors closed
Flood doors open

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TBM with Mechanical Face Support
☺ Rock & firm soil
It usually does not have a pressure chamber to support the

tunnel face
Excavated materials can be transported directly from the cutter

head
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Compressed Air Shield
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Compressed Air Shield
Groundwater-bearing soil
Water penetration can be prevented by:
• Shield
• Part of the tunnel section is protected by a lock system using

compressed air
• Continuous monitoring and automatic adjustment of required

pressure for supporting tunnel face
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Slurry / Hydro-Shield
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Groundwater-bearing soil
Fluid circulation has a double function:

– Mucking
– Face stabilisation water inflow stopped by pressurized
boring fluid (bentonite) inside the cutter-head chamber
Regular pressure is maintained by controlling discharge rates
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1. Cutting wheel
2. Air bubble
3. Bentonite suspension
4. Drive unit
5. Stone crusher
6. Push cylinder
7. Air lock
8. Steer cylinder/shield tail
9. Segment erector
10. Segment conveyor
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Equal distribution of pressures Need of large separation plants for

against mixed-face conditions bentonite treatment
Bad performance in clayey-silty

Good performance in sand and gravel
grounds (polymers addition)
Access to the face (mud-cake +

compressed air)
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EPB Shield
Face supported by
excavated earth
(under pressure inside
the excavation chamber)
Excavation debris is removed from the excavation

chamber by a screw conveyor which allows the
gradual reduction of pressure
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Very well adapted for silty and clayey

Irregular distribution of pressure
grounds (limited or no self supporting
against mixed face conditions
capacity)
No need of separation plant – no Problems when boulders are

bentonite used encountered: no rock crusher
The use of additives (foams) enables

Wearing of the screw can lead to bad
EPB’s to be used with sandy –gravely
pressure distribution
soil (current trend)
More difficult access to the face (no

mud-cake)
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Particle Size Distribution
SOIL
Clay Silt Sand Gravel
100
90
80
70
EPB
60
50
Slurry
Percentage Passing
40
30
20
Hydroshield
10
0
0.001 0.002 0.006 0.02 0.06 0.2 0.6 2.0 6.0 20 60
Fine Coarse Particle Size (mm)
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Double Shield
Gripper + Shield
varying rock formations
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Double Shield
Maintenance problems of articulation

Bigger flexibility
between the shields
A bigger shield surface is not

Higher advancement rates
adapted to squeezing grounds
Avoiding segmental lining when not Performance improvement for a

needed (reduced costs) single shield is not really doubled
Ground treatment and/or probing

More expensive
through the gap between shields
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EPB Mode Slurry Mode
EPB + Slurry
varying soil conditions
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Ground Improvement
When the rock mass is unstable, to ensure the opening stability

Can be a local intervention or a systematic reinforcement
In the first case it represents mainly a temporary solution while
in the second case the ground/rock mass behaviour is
improved and rock/ground changes their characteristics
Tunnel reinforcement should be taken into account when the
support structure is dimensioned and installed
The effectiveness of rock/ground improvements can be
monitored and the solution adapted to advancing conditions
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Ground improvement during excavation
Very low ground cohesion and strength
Unstable excavated length
Pre-driven support: Consolidation:

• Lances • Injection
• Forepoling • Jetting
• VTR face bolting • Freezing (temporary)
• Drainage
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Applicability
Method Ground conditions
Rock mass Ground mass
Cohesive Loose
Cohesive
Stable Unstable Stable Deformable ground Blocks
Unstable
(without cohesion)
Lances ~ ☺ ☺ ☺ ☺ ~ ~
Forepoling ~ ☺ ☺ ☺ ☺ ~ ☺
Jetting ☺ ☺ ☺ ☺ ~
Injections ~ ~ ~ ~ ☺ ~
Freezing ~ ~ ~ ☺
Face
stabilisation ☺ ☺ ~ ~ ~
(VTR bolting)
Drainage ~ ~ ~ ~ ☺
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Lances / “Marciavanti”
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Forepoling
Steel rods ~ 4 m
Prevent large surface

settlements (low
overburden and/or
poor ground)
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VTR face bolting
Lunardi Method
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30
Injection
¸ Ground mass cohesion
Cement Grouts: cement content between 100 and 500 kg per m3 & bentonite. Several
hours must be awaited for setting before any blasting and drilling into the grouted
area.
Micro Cements
Colloidal silica suspensions
Chemical Grouts: Sodium silicate. Reduced setting (30-60 minutes).
Polyurethanes: They react with water and produce foam, which remains ductile after
hardening.
Acrylic Grouts: Liquids of low viscosity. Polymerisation setting on around 1 hour.
Epoxy Resins: Less used.
Thermoplastic materials: Asphalt or melt polyamides pumped with fast flowing water.
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Jetting
¸ quality of the ground around the tunnel
Seal the tunnel against groundwater and thus prevent heading inrushes
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Drainage
Collect water inflow and reduce water pressure
face stabilisation become easier
Ground
Pumping well
Original groundwater table
Lowered groundwater table

Tunnel
Ground
Original groundwater table
Pumping well
Lowered groundwater table
Tunnel
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Freezing
Temporary ground improvement to

avoid water inflow and tunnel
collapse.
Circulation of a refrigerated coolant

through a series of subsurface pipes
to convert soil water to ice & create a
strong and watertight material.
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Selection criteria of excavation methods (1/2)
Geological conditions:
• Rock or soil
• Rock strength and abrasiveness
• Soil cohesion & grains size distribution
• Presence of water
• Homogeneity
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Selection criteria of excavation methods (2/2)
Tunnel depth
Tunnel location (vibration, place)
Tunnel length (costs)
Time (delivery and installation)
Final use
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Tunnel Engineering

Design and Analysis

#03 – Tunnel Excavation Methods

1. Drill-and-blast tunnelling in rocks

2. Roadheader and other excavation machines

3. Tunnel boring machine in rocks

4. Shield tunnelling machine in soils

5. Ground improvements during excavation

6. Selection criteria of excavation methods

• Discontinuous excavation process

• Small advance steps

• Full face or partial face

Continuous mechanized tunnelling

Penetration rate is a function of geological conditions

LOOK OUT < 10 cm + 3 cm/hole depth

Tunnel blasting: one free surface

Second free surface has to be created (cut)

V-cut Fan cut

Explosive powders Less used

ANFO (Ammonium Nitrate – Fuel Oil) Cheap and quite

Emulsions (slurries) Pumpable, water resistant, widespread

The ignition system:

After firing: fumes high temperatures & harmful

Drill & Blast

No protection or support given to the

Requires advancing interruption for

Possibility of excavating tunnels of

Low capital investment (short tunnels) Overbreak

Digger Impact breaker, ripper, pick, and bucket

• Flexibility (weak rocks)

☺ Moderate rock strength (up to 120 MPa)

Extension arm or Boom

Rotating drum Rotating drum

No protection or support given to the

Possibility of excavating tunnels of Suitable to excavate rocks of UCS up

Need to threat dust with sprayed

Low capital investment

Relatively short time from order to

Tunnel Boring Machines

Reaming Competent rock

Open Face Weak, soft rock Firm soil

Mechanical Weathered, highly Firm soil

Shield TBM Compressed Rock-soil mixed Firm soil with

Soil TBM Slurry / Rock-soil mixed Loose sandy

Earth Pressure Rock-soil mixed Soft clay

Double Shield Ground conditions from competent rock

Big circular section:

• 11 m for rock TBM

Mucking & Supporting

Ring erection: short time

Mechanical Face Support

Shield TBM Compressed Air Shield

Soil TBM Slurry / Hydro-Shield

Earth Pressure Balance Shield

Tunnel Reaming & Enlarge Machines

Axial pilot tunnel

Uetliberg Tunnel (Switzerland)

• 14.4 m final section

Competent and hard rock formation - Homogeneity

Single gripper TBM

Double gripper TBM

No protection or support given to the

Suitable to excavate hard rocks of Small flexibility (fault zones, not

Free space for ground probing