Technical note

Project: BMRCL To: Ashish Gaur

Subject: Recommendations of TBM From: Rohit Kumar
Date: 30 Aug 2017 cc:

1. Introduction
This note elaborates the construction sequence for the excavation of bored tunnels using Tunnel Boring
Machine for Bangalore Metro Phase II underground works project. This project comprises of 13.92km of
underground activity divided into four packages (3.67km in package 1, 3.62km in package 2, 3.32km in
package 3 and 3.31km in package 4). Combing all four packages, the project includes 12 UG Stations,10.51km
of TBM excavation for Twin Bored Tunnels, 1 NATM Tunnel, 0.5km of Cut and Cover tunnel works, 5
Launching/Retrieval/Intermediate Shafts and 15 Cross Passages between Bored Tunnels.

Figure 1 BMRCL

2. Construction Sequence for Bored Tunnels

Tunnel construction consists of a variety of activities such as TBM procurement and its mobilization, also
preparation of the work area and assembly of the machine and its components which should be done prior to
the tunnel excavation. The time required for the tunnel excavation can vary depending on the ground conditions
encountered, work area constraints and the number of TBMs used.

Tunnels will be constructed by pressurized face TBMs to optimise the force form the surrounding ground and
reduce the settlement. Also, the tunnel lining can be installed concurrently and without lowering the ground
water levels.

Project 1
Technical note

2.1. TBM staging

Staging area are essential for the tunnel construction. Off street space will be needed for setup, insertion,
operation and extraction of TBMs. Working areas to support tunnel operations, including processing and
removal of spoils, handling precast lining-segments and tunnel utilities such as ventilation, water supply, waste
water removal and power supply.

2.2. Tunnel Lining Construction

Precast concrete segments with gaskets are the first and last support of the tunnel. These segments are
fabricated off-site based on size, grade of concrete, amount of reinforcement and waterproofing details. They
are transported to the site by trucks and stored at the site. The erector installed in TBM will place each tunnel
lining segment to its correct location to build a complete tunnel ring.

Project 2
Technical note
2.3. TBM Tunnel Excavation
The TBM require a launching area to start each tunnelling operation. It will continuously drill that excavate
circular tunnels. As the machine advances, both the ground in front of the machine and the horizontal hole it
creates are continuously supported by TBM shield.

TBMs are normally manufactured in drum shaped steel shield equipped inside with excavation and segment
erection facilities. The fully functional operation of the machine includes the following steps:

1. The rotating cutter head excavates the ground in-front of the machine with the help of hydraulic jacks.
2. The slurry mix provides the face support at TBM face.
3. When certain amount of cutting is done, the TBM cutting operation stops and the erector installed in
the machine place the precast lining segments in their respective location in the ring, provide the
necessary grouting.
4. The TBM advances forward again by applying the hydraulic thrust to previously built tunnel lining.

2.3.1. EPB type TBM

Earth pressure type machine cut the ground with a rotary cutter head. The slurry mixture is injected into the
cutter chamber and is mixed with excavated muck. This mix is pressurized to stabilize the tunnel face and
generate the driving force. Later, the muck is separated from the slurry and discharge be a screw conveyor.

Sometime, highly plastic and dense additive is added to the slurry mix in the cutter chamber to increase the
fluidity and reduce the permeability of the soil.

2.3.2. Slurry Type TBM

In slurry type tunnel boring machine, the cutter chamber is filled with pressurized slurry mix to stabilize the
face of the tunnel. The slurry mix is transported to slurry treatment plant where excavated muck is separated
from the slurry. The excavated much is disposed-off and the slurry is circulated back to the cutter head for re-
use.

Project 3
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2.4. Disposal of Tunnel Muck

In tunnelling activity performed by pressurized-face TBMs, the excavated muck would first undergo some
treatment before being off loaded to disposal sites. With slurry face TBM, bentonite slurry is used to apply fluid
pressure to the tunnel face and to transport soil cutting form the TBM to the surface. The slurry mixed with soil
cutting is processed to separate the soil from slurry in slurry treatment plant after that it is disposed to an offsite
location.

2.5. Tunnel Excavation Settlement and Protection

The TBM machine during operation always excavates slightly more soil than is taken up by the final lining
which commonly referred as ground loss. Such loss can generate undesirable settlement.

The tunnel depth, tunnel size, proximity of adjacent tunnels, ground conditions, TBM characteristics and
excavation techniques can affect the amount ground settlement. Moreover, the requirement for precast tunnel
lining segment, grouted as TBM advances, can also reduce the settlement.

Grouting can be achieved by following ways

Permeation Grouting - adding chemical or cement based grouts into the ground to fill the voids
between soil particles
Compaction Grouting of ground prior to tunnel excavation
Compensation Grouting Grout is injected, thickens the soil above the tunnel and replaces some of
the ground that may be lost during the tunnelling

Project 4