Microtunnelling and Pipejacking

HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
Microtunnelling and Pipejacking

The Herrenknecht Range and Reference Projects
Presented by Ben Hayes
Herrenknecht AG 2013. - The Herrenknecht Company.

Herrenknecht.
Milestones of the company history.
Office and Complete Assembly Total output of

assembly plant product range in China 1.013 bn € 35 years
in Schwanau TBM (Guangzhou) 3,632 employees of Herrenknecht
1980 1999 2005 2008 2012
1977 1998 2002 2011 2014

Foundation of Conversion of Market leader in Final breakthrough at World‘s largest
Herrenknecht GmbH in AG mechanized tunnelling Gotthard Base Tunnel TBM for Hong
GmbH technology Kong, Ø 17.6m
Herrenknecht. Pioneering Underground Technologies

HERRENKNECHT
IN SCHWANAU
} Founded in 1977
} Conversion to Herrenknecht AG in 1998
} Today around 4,800 employees worldwide, 2,000 in Schwanau,
Herrenknecht.
around 200Pioneering
youngUnderground Technologies
people in training
Herrenknecht Group.
Company figures.
} Total output in million Euro } Sales in million Euro

Herrenknecht Group.
Company figures.
} Employees* } Trainees
* Without trainees, including temporary staff

Herrenknecht worldwide.
Subsidiaries and agents.
Russia
UK
Canada Germany Ukraine
Netherlands
Switzerland
USA France Italy
Spain Azerbaijan China
Iran
Mexico
Qatar UAE
Saudi Thailand
Venezuela Arabia
India
Panama Malaysia
Colombia Singapore
Brazil
Australia
Argentina
Chile
Subsidiary
Agent

Herrenknecht Group.
Brands and business areas.
Corporate
Brand
Core
Markets
Core
Brands
Additional Equipment Additional Equipment Additional Equipment
Group
Brands
Services Services Services

Herrenknecht Tunnelling.
Utility Tunnelling – Business Segments.
} Utility Tunnels & Shafts } Pipeline } Energy

} Machine range Ø < 4.2m.
Partial-face
AVN & AVND EPB Shield Gripper TBM Single Shield Double Shield
Excavation Machine
Auger Boring Machine HDD Rig Direct Pipe® VSM

Pipe Express®

Pipe Jacking Jobsite.

Basic Procedure of Pipe Jacking

Machine Types For Microtunnelling (Pipe Jacking)
Open Face Closed Face
MH AVN
TBM AVND
Guided
EPB
Auger

Drive Length and Diameter

Machine Type Diameter Range Maximum Drive
Length
MH DN1700 – DN2500 800m
TBM > DN1200 200m
Guided Auger < DN1200 100m
AVN DN300 – DN800 150m
AVN DN800 – DN1200 200m
AVN DN1200 500m
AVN DN1500 800m
AVN DN1600 – DN3600 1000m +
EPB DN1500 – DN3600 800m

Open Face Shield

Herrenknecht MH Series
Open Shield For Rock Open Shield For Soft Ground

The Open Face Shield Machine

Herrenknecht MH Series
ü û
nRelatively low cost nDifficult when significant
nEasy to operate water ingress present.
nEasy to maintain nDangerous in unstable

ground conditions.
nEasy initial set up
nRelatively slow excavation
process.
nDifficult to deal with mixed
ground conditions.

Open Excavation System

Herrenknecht TBM Series
The Shield The Conveyor Hopper

The TBM Site Set Up

The Open Excavation System

Herrenknecht TBM Series
ü û
nRelatively low cost nCan only be used in dry
nSafe remote controlled ground conditions.
operation nAny running ground
nEasy initial set up due to conditions can prove
minimum back up equipment problematic.
nAble to cope with mixed nUse of skips is safety

ground conditions, including consideration.
very hard rock conditions.
nRapid excavation process

GUIDED AUGER BORING
Microtunneling / Guided auger boring
Microtunneling
Auger rigs with pilot
STRONG PARTNERS FOR SMALL DIAMETERS

GUIDED AUGER BORING
BM 150D piloting

GUIDED AUGER BORING
First extension with casings

GUIDED AUGER BORING
Jacking of product pipes

GUIDED AUGER BORING
Alternative: Second extension

GUIDED AUGER BORING
The Open Face Shield Machine
Guided Auger Systems
ü û
nLow investment nVery limited ground water.
nEasy to operate nLimited ground conditions,
nEasy to maintain displaceable soils only.
nEasy initial set up

nQuick and accurate
installation.

Closed Face Slurry System

Herrenknecht AVN Series

AVN General Arrangement

AVN Excavation Process

SPECIAL PIPE JACKING EQUIPMENT FEATURES TO ENSURE SUCCESS

Slurry & Hydro Shields Equipped with Cone Crusher
n Powerful cone crusher capable of crushing rocks to a pumpable size

n Reduced wear & tear on the cutting wheel
n Increased safety and higher production rates can be achieved

Advanced Slurry Control in Excavation Chamber
n Via remote control the operator can select which slurry nozzles to use
depending on the soil conditions
n Increased safety and higher production rates can be achieved

Medium and High Pressure Slurry Nozzles
n Additional medium pressure nozzles (up to 16 bar) and high pressure

nozzles (up to 300 bar) for increased advances rates in cohesive soil
conditions

Herrenknecht AVN Series
ü û
nSafe remote controlled nMore components for initial
operation set up
nFully closed continuous nSlurry management
excavation system. No skips.
nHigher maintenance in
nCan operate when ground abrasive ground conditions
water is present
nCan operate in all geologies
nLarger diameters can offer
compressed air working for
maintenance

Closed Face Slurry System with

Compressed Air Face Support
Herrenknecht AVND Series

AVND General Arrangement
‘ Bubble Chamber’

AVND Excavation Process


Herrenknecht AVND Series
ü û
nSafe remote controlled nMore components for initial
operation set up
nFully closed continuous nSlurry management
excavation system. No skips.
nHigher maintenance in
nCan operate when ground abrasive ground conditions
water is present
nCan operate in all geologies
nAdded safety when
tunnelling under sensitive
areas.

Closed Face Earth Pressure Balance

System
Herrenknecht EPB Series

EPB General Arrangement

EPB Excavation Process

Application area of EPB technology.
Particle Size Distribution

Sieve Size
Silt Sand Gravel
Clay Fine Medium Coarse Fine Medium Coarse Fine Medium Coarse
100
90
80
Percentage Passing
70
60
50
40
30
20
10
0
0,001 0,002 0,006 0,02 0,06 0,2 0,6 2,0 6,0 20.0 60,0
Particle size in mm
Normally work without foam additives
Only possible with foam additives
Only possible with foam additives / no groundwater presence
Closed Face Earth Pressure Balance

System
Herrenknecht EPB Series
ü û
nSafe remote controlled nUnable to operate
operation effectively in non cohesive
soil conditions
nNo slurry management
required nMaterial disposal can be
problematic
nCan operate when ground
water is present nUse of skips is safety
consideration.
nMost effective excavation
method in cohesive soils.
Clay.
nAdded safety when
tunnelling under sensitive
areas.

Hybrid Systems
‘ EPB Screw ‘Fire Box’ and slurry

Conveyor’ by-pass
arrangement

Fire Box and Slurry By-Pass System
Mode Change
Cylinder

Cutting Wheels
Rock
Mixed Ground
Soft Ground

Machine Choice Table
Rock Head
Mixed Head
Soft Ground
Head

Limitations of Microtunnelling/Pipejacking
Europipe: 3.8m diameter.
2,535m total drive length. Sea Outfall.

Diameter
Herrenknecht Standard Range

Largest Diameter
Extended AVND3000AB
Pipe Dimensions
3.6m ID
4.2m OD
3.0m Long
Approx. Weight
30 Metric Tons

WAN CHAI EAST AND NORTH POINT SEWERAGE TRUNK SEWERS.
CONTRACT NO. DC/2000/11.
Location: Hongkong
Client: DSD Drainage Services

Department
Customer: Fine Projects Ltd.
Geology: Hard Rock (max. 250MPa)
Machine: AVN 600|1200|1800
Tunnel length ID 600: 58m

CONTRACT NO. DC/2000/11. ID1800mm DRIVES.

JOBSITE IMPRESSIONS.
Breakthrough AVN 600

tunnel face in hard rock
JOBSITE IMPRESSIONS.
Machine handling and jobsite installation in dense city area

HYDRO POWER PLANT (HEPP) PROJECT IN AUSTRIA.

PRESSURE WATER TUNNEL MAERZENBACH.
M-974M | HEPP Zillertal | Austria
AVN 1600 TB | OD 1970

Pipe: ID 1500 | Length: 4m
Geology: rock, chist,
quartz, approx. 170 MPA
Tunnel Length: 863m
Contractor: Mauracher Bau
GmbH
Launch of machine
PRESSURE WATER TUNNEL MAERZENBACH.

Altitude difference:
99.24m
Slope: 11,6 %
radius: 1.032m
5 interjacking
stations installed
OLC: Online Load
Control System
installed to prevent
local pipe overloads,
to build a high-
quality tunnel
INSTALLATION OF THE DISTANCE SENSORS .

Sensor 1/2: in jacking pipe no. 3
Sensor 3/4: in jacking pipe no. 30
INSTALLATION OF THE DISTANCE SENSORS .

RECOVERY OF THE MACHINE.

AP LEI CHAU CABLE TUNNEL | THROUGH HARD ROCK | HONG KONG.
Location: Hongkong
Machine: AVN 1800 TB | OD 2150
Pipe: ID 1800 OD 2120
Tunnel length: 2 x 420m
Max. torque: 473kNm
Geology: ignimbrit, welded tuff
Compressive strength: max 411Mpa
Tensile strength: max 19.8Mpa
Chechar index: 5.6
Contractors: Fine Projects Ltd.,

China Complant
Development Ltd
Facing tough hard rock conditions.

Hard rock cutterhead.

Tool replacement.
Tunnel face at 74m.
Interjacking station with cylinders fitted.


Advanced Interjack Stations
Cylinder Support Ring
Stroke Sensor
Reusable Adjustable Seal Ring
Thrust Cylinders
n Bolted multiple-section-design for easy disassembling after completion

of the tunnel and easy reuse for next tunnel
n Increased safety due to reduction of possible leakage using the special
adjustable seal

Reference Project: Christchurch Ocean Outfall.
Sewage outfall tunnel in New Zealand.
} M-1124M, AVND 1800, OD 2145
} Outfall length: 875m (2 more drives: 610m + 830m)
} Geology: sand, silt
} Contractor: McConnell Dowell Construction NZ Pty Ltd.
} Longest Pipe jacking project in Australasia: 875m

Reference Project: Sochi, Russia.
Two pipe jacked outfalls in the Black Sea.
} M-1103M, AVND 2000, OD 2525.
} 2 Sewage tunnels installed under the Black Sea, 1,411m + 2,014m.
} 2,014m = Long distance record in ID 2000.
} Performance: 2,014m tunnel installed in 100 days.
} First Sea Outfall in Russia.

Reference Project: Oran, Algeria.
Magtaa Desalination Plant.
} M-1469M + M-1471M, 2x AVND2500, OD3025
} 3 x 1.280m Intake, 1 x 1.210m Outlet
} Geology: sand, clay, marl

} Groundwater pressure: 2bar
} Best performance: 36m in 24h

Scale (km)
0 5 10
38,7 km
32 Herrenknecht
Tunnelling Machines
in Bangkok
11,8 km 6,8 km
41,9 km 17,8 km
21,6 km
12,4 km 8,8 km
Over 100 km of pipejacking
completed for BMA
5,5 km 4,6 km
BMA Project Overview

Micro Tunnelling – Bangkok - Thailand

PIPEJACKING –EPB2600AE
PIPEJACKING – EPB1400AE – EPB2400AE
n Location: Bangkok
n Project: 230KV
underground
lines from
Lardprao to
Vibhavadi
substations.
n Machine: EPB2600
n Outer diameter: 3,060mm
n Max. torque: 1,375kNm
n Total tunnel length: 7,600m
n Minimum drive: 500m
n Min. Curve radius: 400m
n Geology: Silt, sand, clay
n Contractor: Metropolitan
Electricity
Authority (MEA)
PIPEJACKING –EPB2600AE
PIPEJACKING –EPB2600AE – DRIVE SHAFT

PIPEJACKING –EPB2600AE – DOUBLE PIPE INSTALLATION

PIPEJACKING –EPB2600AE – PROGRESS CHART
439m 419m 365m 420m 426m
MH09 MH10 MH11 MH12 MH13 MH14
Total Drive Length 2,069m

Total Number of Days Production 84 days
Average Production 25m/day
Peak Production 30m/day
Cable Tunnel Korea
n Machine: AVND 2400

n Location: South Korea
n Outer diameter: 3,060mm
n Max. torque: 620kNm
n Total tunnel length: 800m
n Shaft depth: 50m
n 5 curve drives: r=200-250m
n Geology: rock (up to 150 Mpa)
n Contractor: Tuksu Engineering &
Construction Ltd.

Alignment

Pipeline Section

45m Deep Drive Shaft

Short Pipe to Reduce the Deflection
Page 80
Pipe Joint Deflection
Page 81
Finished Curved Tunnel

Summary of Factors When Considering

Microtunnelling Project
1. Ground Conditions.
Good soil investigation is paramount to correct machine choice.
2. Alignment
Be aware of possibilities regarding curves and long drives.
3. Machine Choice
Following analysis of above factors choose the correct machine.

Breakthrough

Microtunnelling and Pipejacking

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HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING

Microtunnelling and Pipejacking

Herrenknecht AG 2013. - The Herrenknecht Company.

Office and Complete Assembly Total output of

1977 1998 2002 2011 2014

Herrenknecht. Pioneering Underground Technologies

Herrenknecht. Pioneering Underground Technologies

* Without trainees, including temporary staff

Herrenknecht. Pioneering Underground Technologies

Herrenknecht. Pioneering Underground Technologies

Additional Equipment Additional Equipment Additional Equipment

Services Services Services

Herrenknecht. Pioneering Underground Technologies

} Utility Tunnels & Shafts } Pipeline } Energy

Auger Boring Machine HDD Rig Direct Pipe® VSM

Herrenknecht. Pioneering Underground Technologies

Herrenknecht. Pioneering Underground Technologies

Herrenknecht. Pioneering Underground Technologies

Machine Types For Microtunnelling (Pipe Jacking)

Open Face Closed Face

Herrenknecht AG 2013. - The Herrenknecht Company.

Drive Length and Diameter

Herrenknecht AG 2013. - The Herrenknecht Company.

Open Face Shield

Open Shield For Rock Open Shield For Soft Ground

Herrenknecht AG 2013. - The Herrenknecht Company.

The Open Face Shield Machine

nEasy to maintain nDangerous in unstable

Herrenknecht AG 2013. - The Herrenknecht Company.

Open Excavation System

The Shield The Conveyor Hopper

Herrenknecht AG 2013. - The Herrenknecht Company.

The TBM Site Set Up

Herrenknecht AG 2013. - The Herrenknecht Company.

The Open Excavation System

nAble to cope with mixed nUse of skips is safety

Herrenknecht AG 2013. - The Herrenknecht Company.

Microtunneling / Guided auger boring

STRONG PARTNERS FOR SMALL DIAMETERS

STRONG PARTNERS FOR SMALL DIAMETERS

First extension with casings

STRONG PARTNERS FOR SMALL DIAMETERS

Jacking of product pipes

STRONG PARTNERS FOR SMALL DIAMETERS

Alternative: Second extension

STRONG PARTNERS FOR SMALL DIAMETERS

nEasy initial set up

STRONG PARTNERS FOR SMALL DIAMETERS

Closed Face Slurry System

Herrenknecht AG 2013. - The Herrenknecht Company.

AVN General Arrangement

Herrenknecht AG 2013. - The Herrenknecht Company.

AVN Excavation Process

Herrenknecht AG 2013. - The Herrenknecht Company.

SPECIAL PIPE JACKING EQUIPMENT FEATURES TO ENSURE SUCCESS

n Powerful cone crusher capable of crushing rocks to a pumpable size

SPECIAL PIPE JACKING EQUIPMENT FEATURES TO ENSURE SUCCESS

SPECIAL PIPE JACKING EQUIPMENT FEATURES TO ENSURE SUCCESS

n Additional medium pressure nozzles (up to 16 bar) and high pressure

Closed Face Slurry System

Herrenknecht AG 2013. - The Herrenknecht Company.

Closed Face Slurry System with

Herrenknecht AG 2013. - The Herrenknecht Company.

AVND General Arrangement