TUNNEL BORING MACHINE

TUNNEL BORING MACHINE

Tunnel boring machines (TBM) are used to excavate tunnels with a circular cross section.
They can be used to bore through hard rock or sand and almost anything in between. Tunnel
diameters can range from a metre (done with micro-TBMs) to 15 metres.
Tunnel boring machines are used as an alternative to drilling and blasting (D&B) methods. A
TBM has the advantages of not disturbing surrounding soil and producing a smooth tunnel
wall. This significantly reduces the cost of lining the tunnel, and makes them suitable to use
in built-up areas. The key disadvantage is cost. TBMs are expensive to construct, difficult to
transport and require significant infrastructure.
DESCRIPTION
CROSS SECTION OF TBM
A tunnel boring machine (TBM) typically consists of one or two shields (large metal
cylinders) and trailing support mechanisms.At the front end of the shield a rotating cutting
wheel is located. Behind the cutting wheel there is a chamber where, depending on the type
of the TBM, the excavated soil is either mixed with slurry (so-called slurry TBM) or left as-
is. The choice for a certain type of TBM depends on the soil conditions. Systems for removal
of the soil (or the soil mixed with slurry) are also present.
Full Face TBM Hydraulic jacks holding a
TBM in place.
Behind the chamber there is a set of hydraulic jacks supported by the finished part of the
tunnel which are used to push the TBM forward. The action here is caterpillar-like. The rear
section of the TBM is braced against the tunnel walls and used to push the TBM head
forward. At maximum extension the TBM head is then braced against the tunnel walls and
the TBM rear is dragged forward.
Behind the shield, inside the finished part of the tunnel, several support mechanisms which
are part of the TBM can be found: dirt removal, slurry pipelines if applicable, control rooms,
rails for transport of the precast segments, etc.
Depending on geology and tunnel requirements, the tunnel may be cased, lined, or left
unlined. This may be done by bringing in precast concrete sections that are jacked into place
as the TBM moves forward, by assembling concrete forms, or in some hard rock geologies,
leaving the tunnel unlined and relying on the surrounding rock to handle and distribute the
load.
The abrasive properties of the rock influence the wear rate of the cutters. The penetration
rate of the full face tunnel boring operation is a function of cutter geometry, machine thrust
and rock strength. That the cutter edge material has become the main limiting element. An
important feature is the distribution of the cutting thrust of around 20 t over a rock contact
area of probably less than 6 cm2. This should be taken into account with the fact that peak
loads of 3 times that magnitude maybe experienced. Consequently the cutter steel needs to
possess high strength coupled with significant abrasive grinding ability.
CUTTER HEAD
CUTTER HEAD
DESCRIPTION
A tunnel boring machine (TBM) consists of a cutter head and trailing support mechanisms.
At the front end of the cutter head a rotating cutting wheel is located. Behind the cutting
wheel there is a backup system. The cutting wheel will typically rotate at 4 to 10 rpm
(depending on size and geology), cutting the rock face into chips or excavating soil (muck).
Depending on the type of TBM, the muck will fall onto a conveyor belt system and be carried
out of the tunnel, or be mixed with slurry and pumped back to the tunnel entrance.
CUTTERS
Cutters from 280mm through 483mm in diameter are available. Discs are available in a wide
range of materials, each material and process type designed for specific geology and project
economics requirements. There are tungsten-carbide-insert rings uses for the most
demanding hard rock applications.
CUTTERHEADS AND CUTTERS
CUTTERS APPLICATION
The rock cutting head of a tunnel boring machine is equipped with an array of
cutters. The cutters used depend upon the ground conditions to be encountered during
tunneling. Drag cutters (picks) tend to be favored for tunneling in soft ground.
In hard rock conditions, drag cutters wear out quickly and can rapidly become
damaged in hard blocky rock situations. Rock breakage has been successfully achieved by
rolling a cutting head across the runnel face; this mode of cutting allows ease of application
of very high thrusts and progressive cutting in hard rock conditions. Such cutters are mounted
on heavy capacity bearings.
Soft ground conditions generally favors drag cutters to be used throughout the cutting
head face, nut in rock conditions various combinations of cutter type and layout are used.
Tunnel boring machine cutting head configurations take three distinct zones into
consideration, namely the centre, the face and the outside edge
TYPES
There are various types of cutter are used depends on soil condition.
Following are the types of cutter used,
1. DISC CUTTERS: This is a simple disc possessing a leading cutting edge which is
replaceable. Some designs incorporate single, double or triple disc cutting configurations.
The principle of excavation of the disc is that of creating a groove in the rock whilst also
applying a shearing force to break off the remaining ridges of rock.Highly abrasive rocks
may present difficulties, however, and place a much lower limit on compressive strength
for the range of application of the disc cutter. Tungsten carbide inserts placed around the
edge of a disc have extended the range of application of such cutters to much harder rocks
2. ROLLER CUTTERS: There are two main types of roller cutter : milled - tooth and
tungsten carbide insert. The milled-tooth design causes rock breakage by localized
penetration. This results in the formation of chips in the immediately adjacent rock by
virtue of a combination of shearing and tensile failure.
Tungsten carbide insert cutters are used especially where the abrasive character of the
rock is beyond the scope of application of the milled-tooth cutter. The rock excavation
process with the tungsten carbide insert roller cutter causes disintegration by virtue of
grinding and pulverizing action rather than by creating fragmented chips of rock.
Although the penetration rate is likely to be slow with the production of large amounts of
fines from high cost cutters, the tungsten carbide roller cutter is probably the most
successful type for the highest strength of rocks likely to be encountered in machine
tunneling.
CLASIFICATION OF CUTTER
Cutters are classified according to their position on cutting head. These are as
under,
1. CENTRE CUTTERS. The central section requires a cluster of cutters to achieve rapid
and effective excavation under relatively slow cutting speed condition. Some cutting
head designs have incorporated cutters arranged as in the form of a tricone
configuration in order to facilitate rock breakage. Relying entirely on rock excavation
by grinding and palavering in this key position can result in slowing tunneling
progress, unless adequate cutting capacity is incorporated.
2. FACE CUTTERS. The main face area is usually excavated by disc or roller cutters,
depending upon the hardness of the rock. Some situations as in weaker rocks may
warrant the use of drag cutters.
3. GAUGE CUTTERS. These are located on the outside edge of the cutting head, and
have the purpose of excavating the opening to the required size.Gauge cutters are
usually disc or roller types and in view of the increased work done by such cutters,
they require to be able to resist the increased wear rate conditions imposed upon them.
CUTTER LIFE
The cutters were changed for such reasons as axle breakage, bearing failure or worm out
cutting edges on one or more of the discs. The average cutter life is 204 m of tunnel driving;
this gave an average consumption of cutters of one per 12 m of tunnel driven. The average
distance traveled by a cutter taking account of its radial position on the cutting head, speed of
rotation and cutting time was calculated to be 640 km.
OPERATION OF TBM
The basic operation of excavation with a tunnel boring machine is the presentation of a
cutting head equipped with suitable cutters to the tunnel face; the cutting head is rotated,
usually at a constant speed, and thrust into the runnel face by a hydraulic pushing system
which itself is secured against the tunnel sides by hydraulic rams.
In tunneling operation the main hydraulic legs incorporate gripper pads with suitable
shoes for thrusting against the tunnel sides during excavation . During the boring operation,
the rotating cutting head is pushed against the tunnel face until the end of the pushing stroke.
The main legs are then retracted for subsequent moving forward in preparation for the next
cutting cycle. Following are the steps of operation of TBM
Step 1
Start of boring cycle.
Machine clamped, rear support legs retracted.
Step 2
End of boring cycle. Machine clamped, head extended rear support legs retracted.
Step 3: Start of reset cycle. Machine unclamped, rear support legs extended.
Step 4:End of reset cycle. Machine unclamped, head retracted. Machine now ready for
clamping and beginning boring cycle.
Excavated rock is removed from the tunnel face by a system incorporated within the
cutting head, a common method being the use of circulating muck disposal buckets which
discharge onto a conveyor system.
BACK UP SYSTEM
BACK UP SYSTEM
Backup systems are provided for traditional rail mucking systems and for continuous
conveyor mucking systems. Backup systems for TBMs ranging from 2.1 meters to 7.5
meters in diameter.
CONVEYOR SYSTEM
It is possible to move over 1000 tons of rock per hour. Conveyor systems easily move the
material over the course of several miles of underground tunnel, The complete system
including head frame, drive unit, tail structure, and belt. Also included are the receiving
hopper and the interface from the horizontal conveyor to the vertical conveyor. It contains
minimum installation costs, high reliability, and efficient operation. It contains equipment
such as stackers, belt storage units, power distribution equipment, control systems,
transformers and switchgear.
PERFORMANCE OF TBM'S IN ROCK.
Tunneling performance based on advance rates in different rock conditions is influenced by
several factors and in particular by TBM capability. Other important factors include
excavated diameter, nature of the ground conditions and in particular the occurrence of
disturbed or highly stressed ground and the presence of groundwater. many factors influence
machine cutting time in addition to maintenance and general operational aspects, which all
contribute to affecting the overall performance of the TBM.
An important aspect influencing TBM penetration rate is that of rock type, and
consequently this its strength. For the weaker types of sedimentary rocks, the penetration rate
increases significantly especially with smaller tunnel diameters. It is appreciated that cutters
usually wear out, but in hard blocky rock conditions some cutters sustain damage or even
complete failure by virtue of high impact loads encountered during face boring.
PART FACE TUNNEL BORING MACHINE
PART FACE TUNNEL BORING MACHINE
Part face tunnel boring machine is used for any shape of tunnel. Part face TBM consists
of boom cutter. A hydraulic pistol is attached to boom for vertical & horizontal control.
Below the cutter head, mucking arm to convey the muck is placed as shown in figure. Rate of
advance of part face TBM is more than drill & blast method but less than full face TBM.
BOOM CUTTER
An alternative excavating method is the use of boom cutter, which, as for the full-faced
machines, may not be mounted within a protective shield. The cutting head can take various
forms, he design taking account of the strength of the rock and the loads imparted through the
cutting tools. In self-supporting rock conditions the boom may be mounted on a crawler
chassis, which may have a cover for protection of the operator from falling debris. Forward
thrust is usually taken to the ground via the crawler tracks but some strutting to the side walls
may be necessary.
PART FACE TUNNEL BORING MACHINE
Part face TBM has both small machines & large machines. Their properties are as shown
below.
Description Small Machine Large Machine
H.P. 80/100 HP 500HP
Weight 10T 80T
Length Of Boom 10 Feet 20 Feet
Max. Section it can tackle 11 Feet Ht 15Feet wide 30 Feet Ht
Both Drill and Blast and Tunnel Boring Machine Method required supporting
system, lighting and ventilation these are described as below.
SUPPORTING SYSTEM
A) SHOTCRETING
Shotcrete and gunite are two commonly used terms for sprayed concrete. Shotcrete is mortar
or concrete conveyed through a hose and pneumatically projected at high velocity onto a
surface. Shotcrete undergoes placement and compaction at the same time due to the force
with which it is projected from the nozzle. It can be impacted onto any type or shape of
surface, including vertical or overhead areas.
Fig. Shotcrete being applied to stabilize a tunnel
The dry mix method involves placing the dry ingredients into a hopper and then conveying
them pneumatically through a hose to the nozzle. The nozzleman who holds the nozzle then
controls the addition of water at the nozzle. The water and the dry mixture is not completely
mixed, but is completed as the mixture impinges on the receiving surface. This requires a
highly skilled nozzleman, especially in the case of thick or heavily reinforced sections. Wet-
mix shotcrete involves pumping of a previously prepared concrete, typically ready-mixed
concrete, to the nozzle. Compressed air is introduced at the nozzle to impel the mixture onto
the receiving surface. The wet-gun procedure generally produces less rebound, waste (when
material falls to the floor), and dusts compared to the dry-mix procedure.
PRECAST SEGMENT
INTRODUCTION
Now a days precast segment is popular in tunneling work due to speedy erection, less back
fill required and high quality. As compared to open trench installations; tunnel lining with
steel liner plates results in less excavation and less backfilling.
INSTALLATION
Steel liner plates are installed to support the soil exposed by tunneling operations. The
outside shape of the liner plates should fit closely to the excavated opening. Where too much
soil is removed, the annular space between the plates and the soil should be backfilled
promptly or temporary supports should be used and the Tab space should be grouted. When
soil conditions are such that the soil may slough or rock falls are possible prior to grouting, a
liner plate thickness must be selected to support these loads with an adequate factor of safety
on bending stiffness. Backfill may consist of pneumatically placed pea gravel, lean grout,
sand, or other suitable material. Some of the liner plates should be provided with grout holes.
A sufficient number should be installed so that grouting can be done effectively at various
locations around the liner periphery. Grout or backfill should be kept as close to the tunnel
face as possible. When grout is used for backfill, it should be injected in lower holes first,
followed by higher holes as the space is filled. Plugs, preferably threaded, should be installed
in holes after their use. With extremely heavy loads, or a tunnel or shaft too large for practical
use of liner plates alone, reinforcing I-Beam rings may be used.
STRENGTH IMPROVEMENT MEASURES: ROCK BOLTING
For strengthening of rock, rock bolting gives good result, following are the two categories of
rock bolting
Rock bolt-group I: act as temporary supports.
a) Split and wedge type bolt: The bolt is split for few centimeters from one of the ends. First
bolt is hammered into the drilled hole. Then the wedge is hammered into the bolt through
split. The wedge expands the bolt, which makes the bolt tight against the wall of hole.
b) Polyester resin anchor bolt) : Polyester resin anchor bolts available in market are of two
types : i) German type ii) English type.
1) German : German resin anchor is placed inside the drilled and cleaned hole and bolt is
inserted inside the hole and rotated which breaks the glass tubes outer and inner both. The
hardener chemically reacts with resin and hardens the mixture of resin and polyester that has
occupied the annular space in ten minutes time.
2) English type: It consists of a plastic cartridge (tube), filed with a mixture of rock powder
and polyester. The hardener is placed between polyester mass and plastic cover. The plastic
cartridge is placed inside the hole and then bolt is forced into the hole and rotated. This
makes the polyester and hardener to react and form a hardened layer within 2 to 3 minutes.
Various types of rock bolts and
washer plates
Polyester resin anchor bolt
The drilled hole must be cleaned before placing cartridge and bolt in it. Also diameter of
hole must be greater than diameter of bolt to permit its rotation.
Rock bolt - group II:
a) Permanent support: such bolts are grouted with cement mortar which avoid rusting and
corroding of bolts and hence last for long period.
The bolt is placed and mortar is poured around the bolt which sets and hardens after
curing time only. Hence such bolts cannot be loaded immediately and also cannot be
pretensioned. During curing period if blasting is done within 40 m to 50 m distance the
mortar can get damaged.
Anchors are of three main types: the expansion shell, the slot and wedge, and the
chemical grout socket. The expansion shell consist of a wedge-shaped plug, screwing on the
end of the bolt and thereby pulled out against outer wedges, or leaves, which are forced
outward against the sides of the hole. Slot and wedge bolts are anchored by driving the
slotted end of the bolt against a wedge at the end of the hole, thereby expanding the end of
the bolt against the sides of the hole.
Bolts are of usually medium tensile steel bar upto 30mm diameter with one end
threaded for nut and washer and the other adapted to the chosen type of anchor. The washers
are flat plates to bear against he rock surface, drilled for grouting if required. Bolt elements
19 mm diameter round steel, threaded at both ends are used with expansion shells. Most
common diameter of bolt vary from 16 mm to 18 mm, having yield stress of 40 to 50
kg/mm
2
. Bolts of stainless steel, known as cromo round, are also used. New bolts of
crome/nickel steel which resist salt water and acid, are also available.
Bearing Plates: Bearing plate may be round, triangular, rectangular, round, spherical
plate with pressed sphere slotted hole and conical in shape. The Principle of prestressing a
bolt means stretching bolt between anchor set in sound rock and the bearing plate on outer
surface of rock.
VENTILATION
Ventilation is the act of supplying fresh air to an area while removing foul air. Therefore
ventilation fans have begun to be installed to discharge the exhaust gas from tunnels and to
supply fresh air into them. Type of ventilation system is selected according to tunnel shape,
tunnel length, size, environmental conditions at tunnel portals, Amount of explosive and
frequency of blasting, Temperature and humidity inside the tunnel etc.
EQUIPMENT FOR VENTILATION:
The equipment's required for tunnel ventilation may either be in the form of suction
pump, compressor, blower fans and pipes. Fans are always driven by electric motor and they
may either be of centrifugal type or turbine type or disc blower type.
Pipes of various varieties such as wire reinforced fabrics, riveted or welded steel
pipes, flexible cloth fabrics, etc. are available for tunnel ventilation. The size of pipes varies
from 100 to 750 mm.
LIGHTING:
Various activities and operations in tunneling work cannot be effectively and
satisfactorily carried out, if there is poor light in the tunnel so proper lighting is necessary.
The spacing of lights will depend on various factors such as tunnel dimensions, size of light
source, nature of rock surface, etc. Now a days Electricity has become most popular way of
tunnel lighting.
ADVANTAGES AND DISADVANTAGES OF METHODS
DRILL AND BLAST METHOD
ADVANTAGE
1. Used in hard rock
2. Initial coast is less
3. Used for any cross-section
DISADVANTAGE
1. Rate of advance is less as compared to other method
2. Skilled labour required
3. More care has to be taken
4. High running cost
5. Over break is more
FULL FACE TUNNEL BORING MACHINE
ADVANTAGE
1. Drive at faster rate of advance
2. Reduce over brake as compared to part face TBM and drill and blast (5 & 20%)
3. Required less concrete for lining
4. Reduce danger of falling rocks
5. Reduction in non productive time, so efficiency of tunnel boring is more
6. Mucking done easily by conveyer belt
7. Reduction in cost up to 40% compared to drill and blast
8. Produce round, smooth and unsheltered base
DISADVANTAGE
1. High initial cost
2. Very high cost of cutter and teeth used for hard rock, and not economically feasible to
use in hard rock
3. High cost of assembling and disassembling (Not economical for short length tunnel)
4. Not suitable to drive other shape section (only circular can drive)
5. Limitations on curves in alignment
PART FACE TUNNEL BORING MACHINE
ADVANTAGE
1. Non-productive time is limited.
2. Muck handling simultaneously.
3. Over break only 2 inches
4. Vibrations are minimum
5. Any curve (radius 100 feet possible)
6. Lower capital cost
DISADVANTAGE
1. Not use in hard rock
2. If used, productivity is less
3. Slower rate of advance compared to full face TBM
COMPARISON BETWEEN DRILL AND BLAST, FULL FACE TBM AND PART FACE TBM
Drill and Blast Part face TBM Full face TBM
Initial Cost Low Low-Medium High
Running Cost High Low Medium
Rate of advance 3-6 m/day 20 m/day 40 m/day
Operating
Radius
No restriction 5m 200-300m
Cross Section Any Dia. 2-6m Dia. 12m Dia.
Over break High Low Low
Support System
Quantity
High Low Low