Components for Tunnel Boring Machines (Erectors,...

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


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

STRATEGIC KEY COMPONENTS FOR TBM’S MANUFACTURERS

Components for Tunnel Boring Machines

(Erectors, Planetary gearboxes, Cutterhead Supports)





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1. Tunnel Boring Machine Segment Erector

We have recently realized one 4 ton- segment erector for a TBM (Tunnel Boring Machine) designed for an

excavation project outside Mae Ngat, Thailandia.

The Tunnel Boring machine, for which the segment erector is intended, has a cutterhead of 4.9 m in diameter

and will be used to excavate an hydraulic tunnel on site.

The erector comprises a rotating structure controlled by two planetary gears with sprocket drives and a crown

wheel. The structure is supported by six rollers and moves on chromium-plated tubular guides.





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The erector is equipped with a mechanical pick-up unit in order to grasp segments.(pick-up two pins). The

mechanical pick-up unit grasps and retains segments for the entire duration of the positioning operations with

three independent movements:

• Swinging = 6°

• Pitch = 6°

• Roll = 6°





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Erector technical data:

• Longitudinal stroke= 1,800 mm

• Overall rotation = ± 200°

• Rotational speed = 2 rpm/minute

• Maximum load = 4 ton

• Weight = 19,000 Kg

• Intrados diameter = 4,200 mm





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2. Videos: 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 ton, for an excavation project in Mae Ngat, in Thailandia.

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

• Axial stroke of the erector.

Link to Youtube: https://www.youtube.com/watch?v=zKGHL7jKio0

• Mechanical pick up unit movement.

Link to Youtube: https://www.youtube.com/watch?v=Pb68K-Aungs

• 90° rotation of segments.

Link to Youtube: https://www.youtube.com/watch?v=uE7L0-OdXGI

• Tilting of gripper.

Link to Youtube: https://www.youtube.com/watch?v=DE-HPX9E_yY





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3.Segment Erector for Tunnel Boring Machine

Galbiati Group has recently realized one 3.5 ton- segment erector for a TBM (Tunnel Boring Machine) designed

for an excavation project outside Shanxi, China.

The erector comprises a rotating structure controlled by two planetary gears with sprocket drives and a crown

wheel. The structure is supported by six rollers and moves on chromium-plated tubular guides.

Below photo of the TBM segment erector set up entirely in the assembly area of Galbiati’s workshop.

The erector is equipped with a mechanical pick-up unit in order to grasp segments. (pick-up two pins).The

mechanical pick-up unit grasps and retains segments for the entire duration of the positioning operations with

three independent movements:

• Swinging = 6°

• Pitch = 6°

• Roll = 6°

• Axial and radial empty stroke of the erector.

Link to Youtube: https://www.youtube.com/watch?v=SH0QxgN67qY

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

Link to Youtube: https://www.youtube.com/watch?v=M0b2cIhikfM





Tel. +39 0341 26 331

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Erector technical data:

• Longitudinal stroke= 1,600 mm



• Maximum load = 3.5 ton







Tel. +39 0341 26 331

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4. Cutterhead Supports for tunnel boring machine (TBM)

We have recently developed two Cutterhead Supports for the cutter head of a TBM designed for an excavation

project in Albania.

Below are a few photos of the TBM control units set up entirely in the assembly area of Galbiati’s factory.





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Some technical data of the Cutterhead supports: a bearing support 4.2 metres wide with a roller bearing 3.2

metres in diameter, 10 planetary gears with a transmitted power of 210 kW each, and a lubrication system. Gross

weight: 60 tons.

The handling of the Cutterhead supports at Galbiati’s factory and the subsequent packaging and transport of

these were particularly complex due to the size and weight of the supports.

The Tunnel Boring machine, for which the control units were intended, will have a cutter head for drilling a

tunnel on site for the promising “Devoll Hydropower Project” in Albania. The project will involve use of the water

resources of the River Devoll which is about 70 km long and situated south-east of the capital of Tehran, and the

construction of a water supply network at Moglicë and Banjia, comprising a hydraulic tunnel in the rock about 6.7

km long. The project is expected to be completed by 2018 and will produce about 729 GWh of electricity a year,

providing Albania with a 20% annual increase in electrical energy.





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5. Tunnel Boring Machine Erectors

Galbiati has recently developed two 7.5 ton- segment erectors for two hard rock double shield TBMs (Tunnel

Boring Machines) designed for an excavation project outside Pfunds, Austria.

The segments erectors are made up of a fixed structure and a moving one, both made of electro-welded

structural metalwork and machined on machine tools.





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The fixed part consists of two longitudinal beams on which the sliding guides of wear-resistant material are

mounted. The mobile part, instead, comprises a fixed ring and a rotating one controlled by two planetary drives

with sprockets coupled with the fifth wheel coupling with internal teeth. The segments that make up the ring are

6: the “invert” segment, or base segment, that weighs 7.5 tons, and five segments (four shoulder segments and a

key segment) each weighing 6 tons.

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°

A prob-drill is also provided with the erectors for carrying out additional drilling operations.

Below photos of the erectors completely assembled at Galbiati workshops.





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Erectors technical data:

• Total beams length = 7,000 mm

• Overall rotation = 220° on both sides


• Maximum load = 7,500 Kg



The Tunnel Boring machines, for which the segments erectors were intended, will have a cutter head 6.5 metres

wide and will be used to drill a hydraulic tunnel for the promising hydroelectric project “Gemeinschaftskraftwerk

Inn”. The project will involve the construction of a water supply network in Tyrol, comprising a hydraulic tunnel

about 22.6 km long that will be drilled using two hard rock double shield TBMs. The network will take 4 years to

complete (2014-2018) and the hydraulic tunnel will produce about 400 GWh of electricity a year from renewable

sources, providing energy for more than a hundred thousand homes.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

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6. Cutterhead Supports for tunnel boring machines (TBMs)

Galbiati has recently developed two bearing supports (Cutterhead Supports) for the cutter head of two hard

rock double shield TBMs designed for an excavation project outside Pfunds, Austria.

Below are a few photos of the TBM bearing supports set up entirely in the assembly area of Galbiati’s workshop.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

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Some technical data of cutterhead supports: a bearing support 4 metres wide with a roller bearing 3.3 metres in

diameter, 7 planetary gears with a transmitted power of 315 kW each, and a lubrication system. Gross weight: 60

tons.

The handling of the bearing supports (Cutterhead Supports) at Galbiati’s assembly shop and the subsequent

packaging and transport of these was particularly complex due to the size and weight of the supports.

Below are a few photos of the TBM bearing supports during the stages of handling and packaging in the Galbiati’s

assembly area.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli


The Tunnel Boring machines, for which the cutterhead supports were intended, will have a cutter head 6.5

metres wide and will be used to drill a hydraulic tunnel for the promising hydroelectric project

“Gemeinschaftskraftwerk Inn”. The project will involve the construction of a water supply network in Tyrol,

comprising a hydraulic tunnel about 22.6 km long that will be drilled using two hard rock double shield TBMs. The

network will take 4 years to complete (2014-2018) and the hydraulic tunnel will produce about 400 GWh of

electricity a year from renewable sources, providing energy for more than a hundred thousand homes.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli


7. Cutterhead Supports for tunnel boring head (TBM)

Galbiati recently designed control units (Cutterhead Supports) for the rotating head of an EPB (Earth Pressure

Balance) tunnel boring machine for an excavation project in Mexico City, Mexico.

Below are a few photos showing the TBM cutterhead supports made entirely in the assembly area of Galbiati’s

factory.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

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A few technical details of the control units: cutterhead support measuring 4.5 m in diameter with roller bearing

measuring 4 m in diameter, 11 planetary gear units with two-speed gearbox – transmitted power of 330KW each,

lubrication system. Overall weight 130 tons.





Tel. +39 0341 26 331

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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.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli


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.


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°

Below photos of the erectors completely assembled at Galbiati workshops.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli


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

Erectors technical data:

• Total beams length = 7,000 mm


• Translation movement speed = N/A

• Rotational speed = max. 2 rpm


• Weight = ~ 25 ton


10. Videos: 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





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

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

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.





Tel. +39 0341 26 331

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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.

The TBM (Dual Mode EPBM), 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:




Via ai Pascoli






Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli


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, we were also invited. Galbiati Group is

recognized internationally for the quality of manufacturing and mechanical engineering, specializing in particular





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in the design and construction of machinery and equipment with high technological content.

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.





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

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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





Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




Via ai Pascoli


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.


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.

• Total beams length: 7,000 mm


• Translation movement speed = 2.800*45 mm/s

• Rotational speed = 2 revolutions per minute








Tel. +39 0341 26 331

Fax +39 0341 26 33 300

Unità produttive:




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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

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