8. Cutterhead Supports for tunnel boring head TBM · The EPB (Earth Pressure Balance) for which the...

Galbiati Group S.r.l.

Sede Legale e Amministrativa:

23848 Oggiono (Lc) Italy

Via Cà Bianca Pascolo, 26

Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:

23848 Oggiono (LC) Italy Via Cà Bianca Pascolo, 26

23841 Annone Brianza (LC) Italy Via ai Pascoli

Cap. Soc. € 500.000,00 - Cod. Fisc. e Part. IVA 03301540963 - VAT IT 03301540963 - R.E.A. LC - 293895

8. Cutterhead Supports for tunnel boring head – TBM

The control units (Cutterhead Supports) designed for an excavation project in Mexico at Galbiati’s factory proved to be a challenge to handle, pack and transport due to the sheer size and weight of the support.

The EPB (Earth Pressure Balance) for which the control units were designed will have a boring head measuring 8.7 metres in diameter and will be used on site to excavate a tunnel for sewerage.

The EPB (Earth Pressure Balance) TBM will be assembled at the site early to mid 2015 and the machine shall be fully operational on site before the summer.

Below are a few photos of the TBM cutterhead supports handled and packed in the assembly area of Galbiati’s factory.

http://galbiatigroup.it/custom-built-machines/tbm-main-bearings-2/

http://galbiatigroup.it/custom-built-machines/cutterhead-support/





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:








Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:








Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:








Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-main-bearings-2/

9. Tunnel Boring Machine Erectors

Galbiati Group has recently built four 4.5 ton- segment erectors for TBM (Tunnel Boring Machine), rotating head, for the excavation of the Qingdao metro.

The segments erectors, built by Galbiati, are identical for both weight and size. They are made up of a fixed structure and a moving one, both made of electro-welded structural metalwork and machined on machine tools.

The fixed part consists of two longitudinal beams on which the sliding guides of wear-resistant material are mounted. The moving part consists of the translating/rotating ring and the pick-up system.

The erectors are equipped with a mechanical pick up unit in order to grasp segments. The mechanical pick up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

Swinging = ± 5° Pitch = ± 5° Roll = ± 5°

http://galbiatigroup.it/custom-built-machines/tbm-main-bearings-2/

http://galbiatigroup.it/custom-built-machines/tbm-erectors/

http://galbiatigroup.it/custom-built-machines/category/tunnel-boring-machines/







Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Below photos of the erectors completely assembled at Galbiati workshops.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




The erectors have also included a coupling plate equipped with bolt benching machine.

Erectors technical data:

Total beams length = 7,000 mm Overall rotation = ± 200° Translation movement speed = N/A Rotational speed = max. 2 rpm Maximum load = 4,500 Kg Weight = ~ 25 ton Intrados diameter = 5,400 mm

Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-erectors/

10. Video: Segment erector for TBM

Galbiati Group has recently designed and built a segment erector for TBM (Tunnel Boring Machine), rotating head with a maximum capacity load of 4.5 ton, for an excavation project in San José de Minas in Ecuador.

Below some videos realized at Galbiati workshops during the final testing of the Tbm segment Erector.

Axial and radial empty stroke of the erector.

Link to Youtube: https://www.youtube.com/embed/Apxa9-yD_DU

Pick up operation.

Link to Youtube: https://www.youtube.com/embed/SoW100G9Drk

Pick up operation and radial and axial translation of the erector.

Link to Youtube: www.youtube.com/embed/L8TczVRHAVs

Link to our website: http://galbiatigroup.it/custom-built-machines/video-tbm-segment-erector/

11. Cutterhead supports for tunnels boring machinery head (TBM)

http://galbiatigroup.it/custom-built-machines/tbm-erectors/

http://galbiatigroup.it/custom-built-machines/video-tbm-segment-erector/

http://galbiatigroup.it/custom-built-machines/erector-for-tbm/



https://www.youtube.com/embed/Apxa9-yD_DU

https://www.youtube.com/embed/SoW100G9Drk

http://www.youtube.com/embed/L8TczVRHAVs

http://galbiatigroup.it/custom-built-machines/video-tbm-segment-erector/

http://galbiatigroup.it/custom-built-machines/cutterhead-supports/





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Galbiati Group builds TBM components for the most important tunnel boring world leaders such as planetary gearboxes, bearing supports (Cutterhead supports), erectors.

Galbiati has recently developed Cutterhead Supports for tunnel TBM rotary boring heads, built for an excavation project in Australia, Queensland.

Here is some technical data for the bearing supports: Cutterhead supports for 5.8 m diameters, with d roller bearings 5,3 mt, 16 planetary gearboxes –Transmitted power of 550 KW each, a lubrication system. Total weight 160 tons.

The movement of the Cutterhead Supports inside the Galbiati workshop and the subsequent packaging and transportation has been particularly complex given the size and weight of the support.

http://galbiatigroup.it/gear-reducers/planetary-drives-for-%E2%80%9Ctbm-rotating-head/

http://galbiatigroup.it/gear-reducers/planetary-drives-for-%E2%80%9Ctbm-rotating-head/

http://galbiatigroup.it/custom-built-machines/tbm-cutterhead-supports/

http://galbiatigroup.it/custom-built-machines/segment-erector/





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

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The TBM (Dual Mode EPBM), in question, which the bearing supports were intended for, shall have an overall diameter of 8 meters, and will perform the digging of the two tunnels providing access to a coal mine. The particular inclination of the tunnel and the massive presence of methane gas will be the two main difficulties encountered during the excavation of the mine.

The work site assembly of the TBM is scheduled for July 1, 2013 and the machine will be fully operational on site between October-November 2013.

Here are some photos of the Cutterhead Supports fully implemented at the mounting area of the Galbiati workshops.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Link to our website: http://galbiatigroup.it/custom-built-machines/cutterhead-supports/

http://galbiatigroup.it/custom-built-machines/cutterhead-supports/





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




12. Testing at the Aprilia plant: Segment erector for TBM

Galbiati Group has set up a group of four segment erectors for each TBM for the Copenhagen Metro excavation project

It was inaugurated in the Aprilia production factory on May 10 2013, the second TBM EPB, (better known as the tunnel boring machine and hence acronym TBM), built by the SELI SpA company, specializing in the excavation of underground tunnels and in the design and implementation of TBM excavation equipment.

The “TBM EPB”, capable of drilling a tunnel with a diameter of 5.78 meters, is an extraordinary giant machine and is the second of a group of four excavation boring machines (this is the technical name), which should be able to create 2 tunnels for a total of 32 km of underground excavations for the fully automated metro line in Copenhagen, which, passes through the city centre providing 17 stations, this will all come into operation by 2018.

It was for this criticality in terms of excavation that SELI was chosen as the contractor of the whole construction project of the four “TBM EPB” for the Copenhagen Metro. The TBM EPB (Earth Pressure Balance) machine, built by Seli in collaboration with Kawasaki, can in fact excavate the ground up to thirty meters deep, providing much greater stability, using the excavated material and maintaining the pressure at the front.

At the testing of the second TBM EPB on May 10, 2013 at the Aprilia plant, Galbiati Group was also invited, the Italian group recognized internationally for the quality of its manufacturing and mechanical engineering, specializing in particular in the design and construction of machinery and equipment with high technological content.


http://www.selitunnel.com/






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

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Galbiati Group was in fact commissioned by Seli, the Roman Contact for the design and implementation of a group of 4 segment positioning erectors, one for each TBM EPB rotating head.

The erector constructed from Galbiati for the second TBM EPB has a diameter of 4,100mm, a maximum capacity of about 4,000 Kg, a total weight of approximately 25,000 Kg and a maximum rotation of 2 rpm.

Afterwards, the video of the testing phase of the segment erector:

Link to Youtube: http://www.youtube.com/embed/gtUi-nSyRaI

Projects like the one just described have enabled the Galbiati Group to be a market leader in Europe and abroad

in the design and construction of manufactured systems at the limit of the current field of metallurgical

technology and mechanical engineering. After a sudden slowdown in investments in the industrial sector and a

slow recovery as the one we are going through, attention to innovation and high-tech production is in fact the

only solution to compete globally.

Link to our website: http://galbiatigroup.it/custom-built-machines/segment-erector/


http://www.youtube.com/embed/gtUi-nSyRaI






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




13. Segment erector for TBM

Manufacture of a segment erector for a TBM (Tunnel Boring Machine) rotating head for tunnel excavation.

The segment erector built by Galbiati is equipped with a mechanical arm with suction cup, so-called vacuum pick up system, positioned in the rear are of the mantle (tail) with the function of moving and put in place the definitive coating segments of the tunnel.

The erector picks up the piece form the sled with a vacuum pick up system with three suction cups (one suction cup is sufficient to support the weight of a segment, to avoid the loss of the load in case of average) and places it in its seat. On proceeds in succession until the last segment (the key segment), which puts in compression the ring. The segments of a ring are bolted together in a radial direction and are connected to the previous ring by means of connectors.

Below the link during the segment erector testing phase at Galbiati Group workshop.

Link to Youtube: http://www.youtube.com/embed/gtUi-nSyRaI

Link to our website: http://galbiatigroup.it/custom-built-machines/erector-for-tbm/

14. Tunnel Boring Machine Erector

Galbiati Group has recently built a 4.5 ton- segment erector for TBM (Tunnel Boring Machine), rotating head, for the excavation of the Bangalore metro.

The segment erector, built by Galbiati, is made up of a fixed structure and a moving one, both made of electro-welded structural metalwork and machined on machine tools.

The fixed part consists of two longitudinal beams on which the sliding guides of wear-resistant material are mounted. The moving part consists of the translating/rotating ring and the pick up system.

Usually positioned behind the cutterhead, the erector is equipped with a mechanical pick up unit in order to grasp segments. The mechanical pick up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

Swinging = ± 5° Pitch = ± 5° Roll = ± 5°

Below there is a photo of the erector being assembled.





http://galbiatigroup.it/custom-built-machines/tunnel-boring-machine-erector/

http://www.youtube.com/embed/gtUi-nSyRaI









Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Erector technical data:

Total beams length: 7,000 mm Overall rotation = ± 200° Translation movement speed = 2.800*45 mm/s Rotational speed = 2 revolutions per minute Maximum load = 4,500 Kg Weight = 27,000 Kg Intrados diameter = 5,600 mm

Link to our website: http://galbiatigroup.it/custom-built-machines/tunnel-boring-machine-erector/

http://galbiatigroup.it/custom-built-machines/files/2012/06/Tunnel_Boring_Machine_Erector-1-di-1.jpg






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




15. Cutterhead supports for TBM (tunnel boring machines)

Cutterhead supports of the TBM (Tunnel Boring Machine) rotating head, excavation diameter from 4 m to more than 12 m. Cutterhead support diameter 5400 mm, with 4000 mm diameter roller bearing and ring gear module 22, nine helical gears with module 22 nine planetary gears with module 22 mm output pinion and lubricating system. Overall weight of cutterhead supports: 100 ton.

Cutteread supports used on TBM machine for excavating water conduits in Ethiopia and China.






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-cutterhead-supports/


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8. Cutterhead Supports for tunnel boring head TBM · The EPB (Earth Pressure Balance) for which the...

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