Mechanized Tunneling Methods for small diameters. · Navigation Systems for Steering of the MTBM....

Mechanized Tunneling Methods for small diameters.

Dr. Gerhard Lang, Business Development Manager, Herrenknecht AG, HK-UT

Kigali, Nov. 6th 2018

Herrenknecht. Pioneering Underground Technologies2

Founded in 1977

Conversion to Herrenknecht AG in 1998

Today around 5,000 employees worldwide, 2,000 in Schwanau,

around 200 young people in training

Contionuous order inflow/output in order of 1.200 to 1.300 billion €

HERRENKNECHT

IN SCHWANAU

Herrenknecht. Pioneering Underground Technologies

Herrenknecht Utility Tunnling.

For all kinds of Tunnelling and Pipeline systems.


Trenchless Installation Methods.

Especially beneficial in urban environments.


Trenchless Solutions for all ground conditions.

Full Face and Part Face excavation.


HEDLINE

Subheadline

Large Diameter TBM History.

Going bigger step by step

2010

Sparvo

15,62 m

1985

HERA

5,95 m

1996

Sydney

10,70 m

1997

Hamburg

14,20 m

2006

Madrid

15,20 m

2006

Shanghai

15,43 m

2016

Santa Lucia

15,87 m

2013

Hongkong

17,6 m


Tuen Mun – Chek Lap Kok Link.

The world‘s largest tunnel boring machine.

Mixshield, Ø17.63m (57.9ft)

2x 4,2km (2.6 mi.) Road Tunnel


The World Record TBM.

Hongkong: Tuen Mun - Chek Lap Kok Link (TM-CLKL).

Mixshield S-880: Ø 17,63 m (57.9ft)

Road tunnel for connection of the Hong Kong-Zhuhai-Macao Bridge

Two additional UT-machines build 47 cross passages


Utility Tunnels & Shafts Pipeline Energy

Herrenknecht Tunnelling.

Utility Tunnelling – Business Segments.

< 4,8m


Benefits of Pipe Jacking Technology vs. Open Trench.

Pipe Jacking below roads – image of a typical construction site.

Control container

Separation

Bentonite

pump

Jacking

frame

Tunnelling

machine

Pipe stock


Example: 1.000m of DN2000 pipe installation at a depth of 12m

Open Trench Trenchless Technology

Construction Time

Working Area

~ 11.000 m² ~ 900 m²


Noise & Dust Pollution

Excavated Material

~ 65.000 m³ ~ 6.500 m³


Example: 1.000m of DN2000 pipe installation at a depth of 12m



Pipe Stress comparison affecting the service life.


After Installation

After approx. 5 years

After approx. 10 years

Different punctual loads

on the pipe caused by

sieve rubble

Filling up of pores with

sieve rubble

Punctual loads on the

pipe increase

Ideal derivation of static

load effects


load


load

All-round even

pipe embedding

No punctual

loads

No punctual

loads

Migrations of fine

particles in the soil

Settlements at

the edges


Geotechnical Aspects for Machine Selection.

Depending on Geology/Hydrology .

Design of the machine / means and methods

Success and failure of the project

Geology or

hydrogeology

Tunnel alignment, gradient

Type of machine (shielded, non shielded)

Face support (Slurry, Mix, EPB)

Cutting wheel design (opening ratio etc.)

Cutting tools: selection and arrangement

Soil conditioning and soil stabilisation

Soil removal (pipes, muck cars, belt conveyors)

Slurry mode: composition of the slurry

EPB: Foam injection capabilites

Rock TBM: Rock stabilization (anchoring etc.)

….


Auger Boring,

Pilote Tube MT

Limited to displacable soils.


GUIDED AUGER BORING WITH PILOTING

APPLICATION FOR JACKING PIPES

3-Step-Method

max. OD 420 mm


PILOTE TUBE and AUGER BORING.

Compact Frames


PILOTE TUBE and AUGER BORING.

Long Frames


Pipe Jacking,

MTBM Technology

> 200mm Pipe ID, in all ground conditions above an

below the groundwater level .


Standard Pipe Jacking.

General Principle.


Standard Pipe Jacking.

Launch shaft design: telescopic vs. indexed jacking frame system.

Slurry wall shaft Telescopic jacking frame Secant pipe shaft with indexed jacking frame


Remote controlled Pipe Jacking operation.

Operation Container – Control Panel – Main Screen.


Navigation Systems for Steering of the MTBM.

Laser or Gyro Navigation Systems for straight and curved drives.

up to 200m

up to 400m

Gyro Navigation system

with hydrostatic water leveling

long distances


Cobbles

Coarse gravel

Medium gravel

Fine gravel

Coarse sand

Medium sand

Fine sand

Sandy, Silty clay

Silt

Clay

–– 10

–– 1

–– 10- 1

–– 10- 2

–– 10- 3

–– 10- 4

–– 10- 5

–– 10- 6

–– 10- 7

–– 10- 8

–– 10- 9

–– 10- 10

–– 10- 11

–– 10- 12

Perm

eab

ility

Facto

r k (

m/s

)

SLURRY

EPB

Application Range of Slurry and EPB.

According the soil type and permeability.


Cutting wheel

Access hatch to cutting wheel

Steering cylinder

Laser target

Screw conveyor

Conveyor belt

Waggon

Power pack

EPB – MTBM with Conveyor Belt and Muck Skip Transport .

ID 1.20m


EPB – MTBM with Muck Skip Transport .

Discontinuous excavation


Slurry Microtunneling: AVN/AVND.

Jobsite setup for Pipe Jacking.

Pipe stockSlurry TBM

Feed and

slurry lines

Main

jacking

station

Control

container

Separation plant

Airlock


Slurry Microtunnelling: AVN/AVND.

Excavation process.


Slurry Microtunnelling: AVN/AVND.

Excavation process.


Soil Adjusted Bentonite Lubrication system.

Bentonite injection scheme.


Tool Changes for Long Distance Pipe Jacking.

Face access >AVN1200 (46“).


Digital Camera System.

Provides insight to the excavation chamber


World Record in Long Distance Pipe Jacking.

Europipe Project - 1994

Drive length 8,317 ft (2.535 m)

Launch shaft Receiving shaft

LeveeLevee Accumersieler

Balje

Sand

0m

-5m

-10m

-15m

-20m

TBM

MTBM OD 149 ” (3.8 m), pipe ID 120” (3,0 m)


Segment Liner TBM

Technology

> 2,0m Pipe ID, in all ground conditions above an below the

groundwater level .


SEGMENT TUNNELING – liner installation.


Machine: MH SM1 Open Shield

(excavator/roadheader)

Diameter: 3.480mm, (11,4ft)

Tunnel length: approx. 4.000m (2,5 mi)

Geology: Gravel, conglomerate, clay,

boulders

No groundwater

Client: Municipality Munich

Contractor: Bilfinger & Berger AG

Open Face TBM – Part Face Excavation.

Hofoldinger Stollen, Munich, Germany.


Displacable supporting

plates in the crown section

Stable tunnel face.

No or little groundwater

Mechanical face support

Open Face TBM – Part Face Excavation.

Hofoldinger Stollen, Munich, Germany.


Segment liner TBM‘S.

Soft ground machines above and below the groundwater table

38

EPB machines Mixshield machines

∅-Range 2.400mm (7.9ft)

GeologySilt, sand, clay, mixed

geology, rock

Groundwater up to 4 bar

∅-Range 2.400mm (7.9ft)

GeologySand, mixed geology,

rock

Groundwater up to 9 bar


39

Single Shield TBM Double Shield TBM

∅-Range 2.400mm (7.9ft)

Geology (instable) Rock

Groundwater no

∅-Range 2.400mm (7.9ft)

Geology (stable) Rock

Groundwater no

Segment liner TBM‘S.

Hard Rock machines


Project in Ghana

KIPP - Kpone Independent Power Project.

AVND 2000, Pipe ID of 2.000mm, Excavation OD 2.425mmm .


41


Seawater intake and outlet tunnel.



Seawater intake and outlet tunnel.

M-2041M, AVND 2000, OD 2425

Location: Tema Industrial Zone, Ghana

2 onshore tunnels: 545m and 520m length

2 offshore tunnels: 380m and 1085m length

Use of tunnel: water intake for PP cooling,

brine outlet

Geology: weathered gneiss

Contractor: JV Bothar Constructions Pty Ltd

& Coleman Tunnelling


“Atui” about to Leave the Factory in Schwanau, Germany.

43


44



Inauguration ceremony on jobsite, April 2016.


Machine in Launch Shaft.

View looking down the

launch shaft when the TBM

has been placed in position

in the jacking rig

Shaft was constructed using

secant piles

Primary benefit is preventing

ingress of ground water into

the shaft

46


Pipe sections & intermediate jacking station

47


48


Subsea recovery of the tunnelling machine.


Project in South Africa

Cape Flats 3 Bulk Sewer Phase 2.

AVN 800, Pipe ID of 800mm, Excavation OD 1.190mmm .


Cape Flats 3 Bulk Sewer Phase 2. Cape Town, South Africa.

M-2014M, AVN800, OD 1190

Location: Cape Town, South Africa

Total Tunnel length: 1200m

Max. drive length: 218m, 5 drives

Jacking pipes: 4m ductile iron

Best daily advance: 25m

Contractor: CSV Construction

Client: City of Capetown

Duration of tunnelling: March –

November 2016


51

Cape Flats 3 Bulk Sewer Phase 2. Cape Town, South Africa.


Together we build our future.THINK

POSITIVE!

[email protected]

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Mechanized Tunneling Methods for small diameters. · Navigation Systems for Steering of the MTBM....

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