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
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Herrenknecht Utility Tunnling.
For all kinds of Tunnelling and Pipeline systems.
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Trenchless Installation Methods.
Especially beneficial in urban environments.
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Trenchless Solutions for all ground conditions.
Full Face and Part Face excavation.
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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
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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
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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
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Utility Tunnels & Shafts Pipeline Energy
Herrenknecht Tunnelling.
Utility Tunnelling – Business Segments.
< 4,8m
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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
Benefits of Pipe Jacking Technology vs. Open Trench.
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
Open Trench Trenchless Technology
Noise & Dust Pollution
Excavated Material
~ 65.000 m³ ~ 6.500 m³
Benefits of Pipe Jacking Technology vs. Open Trench.
Example: 1.000m of DN2000 pipe installation at a depth of 12m
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Benefits of Pipe Jacking Technology vs. Open Trench.
Pipe Stress comparison affecting the service life.
Open Trench Trenchless Technology
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
Ideal derivation of static
load
Ideal derivation of static
load
All-round even
pipe embedding
No punctual
loads
No punctual
loads
Migrations of fine
particles in the soil
Settlements at
the edges
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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.)
….
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Auger Boring,
Pilote Tube MT
Limited to displacable soils.
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GUIDED AUGER BORING WITH PILOTING
APPLICATION FOR JACKING PIPES
3-Step-Method
max. OD 420 mm
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Pipe Jacking,
MTBM Technology
> 200mm Pipe ID, in all ground conditions above an
below the groundwater level .
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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
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Remote controlled Pipe Jacking operation.
Operation Container – Control Panel – Main Screen.
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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
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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.
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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
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EPB – MTBM with Muck Skip Transport .
Discontinuous excavation
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Slurry Microtunneling: AVN/AVND.
Jobsite setup for Pipe Jacking.
Pipe stockSlurry TBM
Feed and
slurry lines
Main
jacking
station
Control
container
Separation plant
Airlock
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Slurry Microtunnelling: AVN/AVND.
Excavation process.
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Slurry Microtunnelling: AVN/AVND.
Excavation process.
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Soil Adjusted Bentonite Lubrication system.
Bentonite injection scheme.
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Tool Changes for Long Distance Pipe Jacking.
Face access >AVN1200 (46“).
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Digital Camera System.
Provides insight to the excavation chamber
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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)
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Segment Liner TBM
Technology
> 2,0m Pipe ID, in all ground conditions above an below the
groundwater level .
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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.
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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.
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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
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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
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Project in Ghana
KIPP - Kpone Independent Power Project.
AVND 2000, Pipe ID of 2.000mm, Excavation OD 2.425mmm .
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41
KIPP - Kpone Independent Power Project.
Seawater intake and outlet tunnel.
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KIPP - Kpone Independent Power Project.
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
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“Atui” about to Leave the Factory in Schwanau, Germany.
43
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KIPP - Kpone Independent Power Project.
Inauguration ceremony on jobsite, April 2016.
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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
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48
KIPP - Kpone Independent Power Project.
Subsea recovery of the tunnelling machine.
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Project in South Africa
Cape Flats 3 Bulk Sewer Phase 2.
AVN 800, Pipe ID of 800mm, Excavation OD 1.190mmm .
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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
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51
Cape Flats 3 Bulk Sewer Phase 2. Cape Town, South Africa.
Herrenknecht. Pioneering Underground Technologies
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