Experiences of TBM operation in gas bearing water condition – A case study in Iran

The Nowsud tunnel (Lot 2B) project is a 25.7 km length water conveyance tunnel which was bored with a 6.73 m diameter double shield TBM. The tunnel consisting of 6.0 m inside diameter which lined with 25 cm thick, 4 pieces honeycomb precast segments. The geology is consisted of limestone, limy shale, black shale and Shally limestone of Cretaceous Garu and Pliocene Gurpi formations. During heading of tunnel, it was encountered with CH₄ gas emission and H₂S bearing water inrushes, up to 890 l/s. A source which could not be plugged with grouting and the heading had to be stopped for several days and months. As far as the author is aware, this condition has not been seen in double shield TBM tunneling.This case study attempts to discuss firstly the quality and origin of poison gases and water ingress into the excavations. Then, the destructive effects of the poison gases and water ingress on different parts of TBM, concrete corrosion, considerable delay in tunnel progresses and negative impact on tunnel personals productivity have been evaluated.Finally, with respect to restricted space in TBM and back up, a executable solution methods have been pursued to abatement and prevention of the poison gases and water ingress into the excavations, while the construction is in progress by double shield TBM.     

Estimation of deformation and stiffness of fractures close to tunnels using data from single-hole hydraulic testing and grouting

Sealing of tunnels in fractured rocks is commonly performed by pre- or post-excavation grouting. The grouting boreholes are frequently drilled close to the tunnel wall, an area where rock stresses can be low and fractures can more easily open up during grout pressurization. In this paper we suggest that data from hydraulic testing and grouting can be used to identify grout-induced fracture opening, to estimate fracture stiffness of such fractures, and to evaluate its impact on the grout performance. A conceptual model and a method are presented for estimating fracture stiffness. The method is demonstrated using grouting data from four pre-excavation grouting boreholes at a shallow tunnel (50 m) in Nygård, Sweden, and two post-excavation grouting boreholes at a deep tunnel (450 m) in Äspö HRL, Sweden. The estimated stiffness of intersecting fractures for the boreholes at the shallow Nygård tunnel are low (2–5 GPa/m) and in agreement with literature data from field experiments at other fractured rock sites. Higher stiffness was obtained for the deeper tunnel boreholes at Äspö which is reasonable considering that generally higher rock stresses are expected at greater depths. Our method of identifying and evaluating the properties and impact of deforming fractures might be most applicable when grouting takes place in boreholes adjacent to the tunnel wall, where local stresses might be low and where deforming (opening) fractures may take most of the grout.     

Drip sealing of tunnels in hard rock: A new concept for the design and evaluation of permeation grouting

This paper presents a new pre-excavation grouting concept to prevent dripping and reduce the inflow into a railway tunnel. For this purpose, the tunnel’s roof was drip-sealed using colloidal silica and the walls and invert of the tunnel were grouted with cement. The grouting design process followed a structured approach with pre-investigations of core-drilled boreholes providing parameters for the layout. Water pressure tests and pressure volume time recordings were used for the evaluation. Results showed that the design was successful: the total transmissivity was reduced from 4.9 × 10^?08 m²/s to the measurement limit (1.6 × 10^?08 m²/s), and the dripping was reduced to eight spots from the roof. Improved rock characterisation showed that the grout hole separation was within the transmissivity correlation length and that grouting efficiency depends to a large extent on the dimensionality of the flow system of the rock mass.     

Performance characteristics of tunnel boring machine in basalt and pyroclastic rocks of Deccan traps–A case study简

A 12.24 km long tunnel between Maroshi and Ruparel College is being excavated by tunnel boring machine (TBM) to improve the water supply system of Greater Mumbai, India. In this paper, attempt has been made to establish the relationship between various litho-units of Deccan traps, stability of tunnel and TBM performances during the construction of 5.83 km long tunnel between Maroshi and Vakola. The Maroshi–Vakola tunnel passes under the Mumbai Airport and crosses both runways with an overburden cover of around 70 m. The tunneling work was carried out without disturbance to the ground. The rock types encountered during excavation are fine compacted basalt, porphyritic basalt, amygdaloidal basalt, pyroclastic rocks with layers of red boles and intertrappean beds consisting of various types of shales. Relations between rock mass properties, physico-mechanical properties, TBM specifications and the corresponding TBM performance were established. A number of support systems installed in the tunnel during excavation were also discussed. The aim of this paper is to establish, with appropriate accuracy, the nature of subsurface rock mass condition and to study how it will react to or behave during underground excavation by TBM. The experiences gained from this project will increase the ability to cope with unexpected ground conditions during tunneling using TBM.     

Analyses of the grouting results for a section of the APSE tunnel at Äspö Hard Rock Laboratory

The grouting results for a tunnel at a depth of 450 m in crystalline rock at Äspö HRL were studied. The aims were to investigate whether the methodology used resulted in a successful grouting design and producing a sufficiently dry tunnel, and whether grout penetration and inflow into the finished tunnel corresponded to the predictions. An analysis was made of data from an original cored borehole, drilled before the tunnel was constructed and mapped thoroughly with regard to fractures and transmissivities. The predicted inflow into the tunnel was calculated and found to be four times higher than the measured inflow. The latter was 5 l/min along the 70 m tunnel, considered to be a good result at the current depth. New cored control boreholes were drilled along a section of the tunnel. The inflow positions and quantities in these holes, and the positions of grout found in the corresponding cores, were compared with the data from the original borehole. It was found that at the predicted positions of larger fractures, grout was observed and there was no inflow, showing that these had been successfully sealed. At the predicted positions of small fractures, no grout was visible in the cores, and small inflows showed that the grout had not sealed these fractures. The results indicated that cement-based grout successfully sealed fractures down to a hydraulic aperture of about 50 μm but not below 30 μm. This concurs with the initial design aimed at sealing fractures larger than 50 μm.     

Design and construction of river crossing tunnel beneath Tachia River,Taiwan

Due to the impact of the 1999 Chi-Chi earthquake (ML = 7.3) and the following typhoon induced heavy rainfalls and floods, the tailrace tunnel of the Kukuan Hydropower Plant was severely blocked and must be realigned and rebuilt. The new tailrace tunnel is 1991 m long with a 140 m section passing underneath the Tachia River, where the shallowest rock cover is 3.5 m. In view of the common phenomenon that weak zone developed along river channel and debris accumulated on river bed, the ground improvement from the surface to the tunnel is difficult. Therefore, a construction shaft, a water sealing pre-grouting plan and a special supporting system were designed to prevent the potential water inflow when tunneling underneath the Tachia River. In the construction phase, adequate excavation cross sections, support elements, auxiliary treatments, and water sealing grouting methods were selected to overcome the difficult ground condition encountered. The experience learned from this successful case can be a valuable reference for the design and construction of similar river crossing tunnels in the future.     

A case study on rock damage prediction and control method for underground tunnels subjected to adjacent excavation blasting

The effects of tunnel blast excavation on the surrounding rock mass and the lining systems of adjacent existing tunnels are comprehensively studied for the Damaoshan highway tunnel project as a case study. The damage of the surrounding rock and the lining system under different blast loads are analyzed by field tests and numerical simulations. It is observed that the rock damage extent around the tunnels linearly increases with the peak particle velocity (PPV) of the existing tunnel. A feasible PPV-based damage control method is then proposed for different portions of the tunnels. For the Damaoshan tunnel project, a PPV threshold of 0.22 m/s in the adjacent existing tunnel is prescribed to limit the damage extent to approximately 1.6 m at the tunnel exit and entrance portions. Furthermore, the PPV criteria for the other portions are also determined accordingly. It is also shown that no failure occurs in the linings or at the rock–lining interfaces if the PPV is less than 0.30 m/s. The control method and the threshold PPV proposed in this study have been successfully applied to restrict blast-induced damage during the new tunnel excavation of the Damaoshan tunnel project.     

Key protection techniques adopted and analysis of influence on adjacent buildings due to the Bund Tunnel construction

The Bund Tunnel is 14.27 m in diameter. It is the first application of super diameter earth pressure balanced shield (EPBS) in China. There are many historical buildings along the construction line, and the minimum horizontal distance from the building to the tunnel side varies from 1.7 m to 30 m. Considering the importance of these historical buildings and the complicated construction processes, it is essential to adopt effective protection techniques to ensure safety during the tunnel construction. Three kinds of protection techniques are presented in this paper. Firstly, underground cut-off wall built by bored piles is used to separate the buildings and tunnel when the minimum horizontal distance from the building to the tunnel side is less than 5 m. Secondly, the grouting reinforcement technique is adopted when the minimum clear distance is between 5 m and 10 m. Finally, if the minimum clear distance is larger than 10 m, the optimized construction parameters are selected to reduce the influence induced by the EPBS excavation. The deformations of some typical buildings are monitored. The results of this project will be a useful reference for similar future projects.     

Acoustic emission monitoring of rockbursts during TBM-excavated headrace tunneling at Jinping Ⅱ hydropower station

To better understand the mechanical properties of marble at Jinping II hydropower station, this paper examines the changes of brittle rocks in excavation damaged zones(EDZs) before and after excavation of tunnel with the tunnel boring machine(TBM). The paper attempts to employ the acoustic emission(AE) to study the AE characteristics and distribution of rockburst before and after TBM-excavated tunnel. It is known that the headrace tunnel #2, excavated by the drill-and-blast(D&B) method, is ahead of the headrace tunnel #3 that is excavated by TBM method. The experimental sub-tunnel #2–1, about 2000 m in depth and 13 m in diameter, between the two tunnels is scheduled. In the experimental sub-tunnel #2–1, a large number of experimental boreholes are arranged, and AE sensors are installed within 10 m apart from the wall of the headrace tunnel #3. By tracking the microseismic signals in rocks, the location, frequency, quantity, scope and intensity of the microseismic signals are basically identifed. It is observed that the AE signals mainly occur within 5 m around the rock wall, basically lasting for one day before tunnel excavation and a week after excavation. Monitoring results indicate that the rockburst signals are closely related to rock stress adjustment. The rock structure has a rapid self-adjustment capacity before and after a certain period of time during tunneling. The variations of rock stresses would last for a long time before reaching a fnal steady state. Based on this, the site-specifc support parameters for the deep tunnels can be accordingly optimized.     

Subsurface exploration and transient pressure testing from a deep tunnel in fractured and karstified limestones (Lötschberg Base Tunnel,Switzerland)

This paper summarizes the results from a subsurface exploration campaign carried out in fractured and karstified limestones and marls of the Lötschberg Base Tunnel in the Swiss Alps. The exploration program in the 3.2 km long Doldenhorn Section consisted of 50 cored and 13 destructive horizontal predrillings of 250–300 m length each (in total 14,853 m of predrillings). These boreholes were used to locate possible tunnel inflows and characterize their hydraulic properties. A new efficient hydrogeological test protocol has been developed and was systematically and successfully applied. The test protocol consists of short constant rate outflow and recovery tests in open boreholes. The on-site test analysis allowed reliable predictions of the hydrogeological conditions ahead of the advancing tunnel face in brief period of time, leading to decisions regarding further reconnaissance drillings, tunnel driving or sealing measures. Detailed analysis of the transient pressure responses of the hydrogeological tests carried out after tunnel completion led to important new findings regarding flow model identification (type and orientation of conductive fractures), aquifer parameters and boundary effects. Even though the hydrogeological tests had to be carried out within a short time frame (a few hours) they allowed characterization of large scale aquifer properties relevant for long term tunnel inflow behavior.     

Characteristics and mechanisms of large deformation in the Zhegu mountain tunnel on the Sichuan–Tibet highway

The Zhegu mountain tunnel is a typical long, deep-buried highway tunnel at a high altitude, subjected to low temperatures and high geostress. The tunnel is excavated in carbon phyllite and slate at depths of up to 1000 m below ground, which has resulted in extreme deformation, especially in a depth of 3 m from the tunnel perimeter. The maximum deformation was monitored to be 60 cm, with a maximum deformation speed of 39.3 mm/day. In addition, it took 60–120 days to complete 90% of the deformation. The deformation of the Zhegu mountain tunnel is characterized by serious subsidence of the arch, squeezing outwards of sidewalls, buckling failure of sidewalls and local collapse. The swelling of soft rock is found not to be a main factor of large deformation in the subject tunnel. Three mechanisms of large deformation are derived based on the characteristics and geological conditions, which are plastic flow of soft rock, shear sliding of wedges, and bending of thin-layered soft rock.     

A new tunnel inflow classification (TIC) system through sedimentary rock masses

A new classification system with respect to the engineering geological characteristics of rock masses in different geological conditions were presented based on the authors’ experiences and observations. Rock mass composition (RMC), rock type (RT), clay-bearing content (CBC), unconfined compressive strength (UCS) and tunnel depth (TD) were found as the major factors affecting the tunnel inflow. In order to minimize judgmental bias and set up a basic database, data pertaining to these factors were compiled from 33 tunnels project with a total length of about 200 km thoroughly excavated in sedimentary rocks. The classification factors were rated using a combination of the analytic hierarchy process (AHP) and statistical methods. In order to cover all rock mass varieties and lessen the uncertainties, major factors were divided into categories of varying quality. Two statistical criteria were introduced to calculate the weighing of categories. The main advantage of this procedure is its capability of effectively predicting groundwater inflows in a vast variety of geological conditions especially from a single flow pathway such as a brittle fault zone to low permeable rock masses. The proposed classification was applied to the actual rock tunnels. It was revealed that the predicted values were in a good agreement with the actual field measurements and could provide quantitative measures of tunnel inflow. The proposed method could be more feasible for a reliable pre-assessment of groundwater inflows in the future tunnel construction projects under heterogeneous geological conditions. Furthermore, the most important factors as well as their combination are introduced for sedimentary rocks.     

Correlation of rock cutting tests with field performance of a TBM in a highly fractured rock formation: A case study in Kozyatagi-Kadikoy metro tunnel,Turkey

This paper presents and discusses detailed field and laboratory studies concerning boreability prediction of tunnel boring machines (TBMs) used in Kozyatagi-Kadikoy metro tunnels in Istanbul in a highly fractured rock formation. The determination of some design parameters and performance prediction of a tunnel boring machine (TBM) are carried out using full-scale rock cutting test. The intact rock samples having minimum sizes of 1.0 × 0.7 × 0.7 m are obtained from shale and limestone (Kartal Formation) along the tunnel line. The rock samples are subjected to full-scale laboratory rock cutting tests with different depth of cut and cutter spacing values using a constant cross section (CCS) disc cutter of 330 mm in diameter. Cutter forces, i.e., thrust force, rolling force and specific energy values are recorded for each cut. The results of the tests are first used to calculate TBM design and performance parameters such as torque and thrust requirements and cutting rates. In the second part of the research, the field performance of the TBM is recorded with the aid of data acquisition system installed within TBM and the predicted performance and design values obtained from full-scale rock cutting tests are compared with the field values. It is observed that fractured characteristics of the rock formation affect tremendously TBM performance and predicted values differ from the field data in some extend. It is believed that the results will serve as a guide for efficient selection and use of TBMs.     

Assessing the efficiency and applicability of contact grouting in the Istanbul Subway

 Contact grouting is used to fill the cavities between tunnel linings and the host rock and for sealing the joints against water penetration. This paper discusses the modelling of the movement of grout through the Thracian Formation in which the Mecidiyekoy and Gayrettepe stations of the Istanbul Subway were constructed. Water ingress into the tunnel occurred in the strata, which had hitherto been considered relatively impermeable. The model indicated the sections in which grouting was most effective and provided the basis on which more realistic calculations of grout requirements for other sections of the works could be made. Received: 17 February 2000 · Accepted: 29 August 2000     

Investigation and assessment of pre-grouted rock mass

Pre-grouting is a technique for reducing water ingress into tunnels and caverns by grouting fractures and joints prior to excavation. This study investigates pre-grouted rock mass to evaluate grout penetration in fractures and transmissivity of water in the rock mass surrounding the built tunnel, with the use for core drilling, OTV, high-precision water injection tests and core logging. The study was performed in three tunnel localities, in tunnels excavated in connection with the Follo Line project in Norway, where pre-grouting was performed using cement-based grouts. It was found less cement than expected in fractures with small apertures, compared with results of grout penetrability in laboratory studies of similar grouts. Further, it was found that fractures in coarse-grained rock types had rougher fracture surfaces and higher hydraulic apertures, than fractures in fine-grained rock types. It was also found that fractures with smoother surfaces had smaller hydraulic apertures in general. Hydraulic jacking was evidenced during the pre-grouting in this area, which is likely to have contributed to unnecessary high grout consumption.

     

Information and knowledge behind data from underground rock grouting

Data related to the pre-grouting work of a large underground project are systematically analyzed to reveal the mechanism behind, to shed some light on the execution of practical grouting, and to enrich the theory of engineering geology. Grouting is generally taken as an effective way for controlling non-ignorable water seepage during underground rock excavation. Though various models have been developed to guide grouting design or to specify criteria for grouting stop, it does not change the fact that grouting is still highly experience-based. Therefore, explanation of the current situation due to grouting complexity is given through step-by-step data analysis, where the impact on grouting parameters from the geological and hydrogeological conditions is investigated, and the grouting features of two tunnels located at the same depth below the sea surface are compared and discussed. Then, the data from individual grout hole are used to construct the regional geological conditions via inverse analysis. It is found that grouting of fractured rock masses is accompanied with great uncertainty, and field grouting data can contribute significantly to a better understanding of the regional geological conditions around an underground tunnel or rock cavern.     

Treatment design of geological defects in dam foundation of Jinping I hydropower station

Jinping I hydropower station is one of the most challenging projects in China due to its highest arch dam and complex geological conditions for construction.After geological investigation into the dam foundation,a few large-scale weak discontinuities are observed.The rock masses in the left dam foundation are intensively unloaded,approximately to the depth of 150–300 m.These serious geological defects lead to a geological asymmetry on the left and right banks,and thus some major diffculties of dam construction are encountered.In this paper,the influences of geological defects on the project are analyzed,followed by the concepts and methods of treatment design.Based on the analysis,the treatment methods of the weak rock masses and discontinuities are carefully determined,including the concrete cushion,concrete replacement grids,and consolidation grouting.They work together to enhance the strength and integrity of the dam foundation.Evaluations and calibrations through geo-mechanical model tests in combination with feld monitoring results in early impoundment period show that the arch dam and its foundation are roughly stable,suggesting that the treatment designs are reasonable and effective.The proposed treatment methods and concepts in the context can be helpful for similar complex rock projects.     

Evaluation of common TBM performance prediction models based on field data from the second lot of Zagros water conveyance tunnel (ZWCT2)

Zagros water conveyance tunnel (ZWCT) is a 49 km tunnel designed for conveying 70 m³/s water from Sirvan River southward to Dashte Zahab plain in western Iran. This long tunnel has been divided in 3 Lots namely 1A, 1B, 2. By November 2014, about 22 km of the Lot 2 (with a total length of 26 km) has been excavated by two double shield TBMs from two southern and northern portals. The bored section of tunnel passed through different geological units of 3 main formations of Zagros mountain ranges which mainly consist of weak to moderately strong argillaceous-carbonate sedimentary rocks. In this paper, the operating and as-built geological data collected during construction phase of the Lot 2 of ZWCT project was used to compare the calculated machine performance by empirical methods such as the Hassanpour et al. (2011), Q_TBM, NTNU, Palmstrom, and theoretical model of Colorado School of Mines or CSM. The predicted penetration rates were then compared with the observed field performance of the machine and the variations of predicted rates were examined by statistical analysis. The results showed that the site-specific model, which was based on TBM performance in similar formations can provide estimates closer to actual machine performance.     

Effect of adverse geological condition on TBM operation in Ghomroud tunnel conveyance project

With the planned length of 36 km, Ghomroud tunnel is one of the longest tunnels under construction in central Iran. About half or 18 km of this tunnel was excavated by a double shield TBM. Several adverse geological conditions encountered, consisting of ground squeezing and face collapse, hindering TBM performance, and caused several TBM stoppages and jamming. This paper presents the impact of ground conditions on machine performance based on the information obtained from field observations and geotechnical site investigations. As built geological conditions are described while the method and results of tunnel convergence measurements and their impacts on tunneling operation is examined. Based on the detail study of the available geological information and tunnel convergence measurements, it was evident that the existence of weak structures in rock mass resulted in high rate of the convergence, which was the dominant factor in the TBM jamming. Since it was not possible to make observation and measurements of geological parameters when working in a lined tunnel built by a shielded machine, an attempt was made to correlate TBM operational parameters and ground convergence. The preliminary result of the analysis has indicated a good correlation among machine’s operational parameters and tunnel convergence. If the system is fully developed, these parameters can be used as an indicator of the potential for high rates of convergence. An early warning on ground convergence is essential for taking precautionary measures to avoid TBM from getting jammed by squeezing ground.     

Experimental study of the effectiveness of a water system in blocking fire-induced smoke and heat in reduced-scale tunnel tests

A water system, consisting of several water mist nozzles, has been installed in a reduced-scale tunnel. Its effectiveness in blocking fire-induced smoke and heat is tested, with and without longitudinal ventilation. A total of 14 fire tests have been carried out, with 250 ml methanol in an iron tray (25 cm × 20 cm) as fuel. Temperatures have been measured by 30 thermocouples, located upstream and downstream of the fire location. The aim is to assess the effectiveness of the water system in preventing smoke spread and in reducing the temperature in the tunnel. Interaction of the water with the fire is avoided. The impact of water pressure, ventilation velocity and nozzle arrangement on the effectiveness in smoke blocking and temperature reduction is discussed. The result confirms that the water system effectively reduces the temperatures and prevents smoke spreading in the absence of longitudinal ventilation. However, strong longitudinal ventilation (0.8 m/s ventilation velocity in the reduced-scale tunnel, corresponding to critical velocity in full-scale (1:10) tunnel) reduces the effectiveness in blocking the smoke spreading by the water system, although the temperature reduction downstream the water system remains in place. Higher water pressure makes the cooling effect stronger, because more and smaller water droplets are injected into the tunnel. For a given level of water pressure level, the impact of the nozzle row configuration is small in the tests.