TBM Excavation in Difficult Ground Conditions E-Book

Nuh Bilgin

• Herausgeber: Wiley-VCH
• Kategorie: Wissenschaft und neue Technologien
• Sprache: Englisch

Seitenzahl: 414

Veröffentlichungsjahr: 2016

Beschreibung

The book relates experience of TBM drives in difficult geology, making use of case studies from Turkey to demonstrate the influence of the local geotechnical conditions on the selection of a tunnel boring machine and the selection of tools. There is an extensive description how various geological phenomena, such as for example transition zones, dikes, rock discontinuities, blocky ground, squeezing ground, swelling clays and high strength and abrasive rocks, can reduce the advance rate and what countermeasures can be introduced. There is also a discussion of necessary advance probing and safety measures. Since the presented practical experience from Turkey can also be applicable for other tunnel projects in difficult geology, the book represents a valuable source of knowledge for every tunneler.

Leseprobe

Table of Contents

Cover

Title

Copyright

Dedication

Preface

Acknowledgements

About the Authors

1 Introduction

2 Geology of Turkey and Istanbul, expected problems, some cuttability characteristics of the rocks

2.1 Introduction

2.2 Geology of Turkey

2.3 Geology of Istanbul

2.4 TBM performance in different projects in Istanbul

2.5 Description of geological formations in Istanbul, physical and mechanical properties

2.6 Full-scale linear rock cutting tests with disc cutters in rock samples collected from different projects in Istanbul

2.7 Conclusions

References

3 Difficult ground conditions dictating selection of TBM type in Istanbul

3.1 Introduction

3.2 Case study of open TBM in complex geology (1989), in Baltalimani tunnel: Why open type TBM failed

3.3 Double shield TBM in the Istanbul–Moda collector tunnel, 1989/90

3.4 Double shield TBM working without precast segment, difficulties in difficult ground: Tuzla-Dragos tunnel in Istanbul

3.5 Difficulties in using slurry TBMs in complicated geology, Marmaray tunnel project

3.6 Difficulties in single-shield TBM working in open mode in complex geology: An example from Kadikoy–Kartal metro tunnel

3.7 Eurasia tunnel excavated by a large diameter slurry TBM

3.8 Conclusions

References

4 Difficult ground conditions affecting performance of EPB-TBMs

4.1 Introduction

4.2 Factors affecting performance of EPB-TBMs

4.3 Performance prediction of EPM TBMs in difficult ground conditions

4.4 Conclusions

References

5 Selection of cutter type for difficult ground conditions

5.1 Introduction

5.2 Comparative studies of different type of cutters for Tuzla–Dragos tunnel in Istanbul – test procedure and results

5.3 The inefficient use of tungsten carbide studded disc cutters in the Marmaray–Istanbul project

5.4 Conclusions

References

6 Effects of North and East Anatolian Faults on TBM performances

6.1 Introduction

6.2 Kargi tunnel

6.3 Gerede tunnel

6.4 Dogancay energy tunnel

6.5 Nurdagi railway tunnel

6.6 Uluabat energy tunnel

6.7 Tunnels excavated by drill and blast methods

6.8 Conclusions

References

7 Effect of blocky ground on TBM performance and the mechanism of rock rupture

7.1 Introduction

7.2 Mechanism of rock rupture and face collapse in front of the TBM in the Kozyatagi–Kadikoy metro tunnels in Istanbul

7.3 Conclusions

References

8 Effects of transition zones, dykes, fault zones and rock discontinuities on TBM performance

8.1 Introduction

8.2 Beykoz sewerage tunnel

8.3 Kartal–Kadikoy metro tunnels, methodology of understanding critical zones

8.4 Conclusions

References

9 Squeezing grounds and their effects on TBM performance

9.1 Introduction

9.2 Basic works carried out on squeezing ground

9.3 Uluabat tunnel

9.4 Kargi Tunnel

References

10 Clogging of the TBM cutterhead

10.1 Introduction

10.2 What is clogging of a TBM cutterhead and what are the clogging materials?

10.3 Testing clogging effects of the ground

10.4 Mitigation programs to eliminate clogging

10.5 Clogging of TBMs in Turkish projects

10.6 Conclusions

References

11 Effect of high strength rocks on TBM performance

11.1 Introduction

11.2 Beykoz sewerage tunnel, replacing CCS disc cutters with V-type disc cutters to overcome undesirable limits of penetration for a maximum limit of TBM thrust

11.3 Nurdagi tunnel, full-scale cutting tests to obtain optimum TBM design parameters in very high strength and abrasive rock formation

11.4 Beylerbeyi–Kucuksu wastewater tunnel, TBM performance in high strength rock formation

11.5 Tuzla-Akfirat wastewater tunnel, TBM performance in high strength rocks

11.6 Conclusions

References

12 Effect of high abrasivity on TBM performance

12.1 Introduction

12.2 Determination of the abrasivity

12.3 Empirical prediction methods for disc cutter consumption

12.4 Examples of cutter consumptions on TBMs in Turkey

12.5 Conclusions

References

13 Effect of methane and other gases on TBM performance

13.1 Properties of methane

13.2 Selimpasa wastewater tunnel, methane explosion in the pressure chamber of an EPB-TBM

13.3 Gas flaming in the Silvan irrigation tunnel

13.4 More gas-related accident examples for mechanized tunneling

13.5 Conclusions

References

14 Probe drilling ahead of TBMs in difficult ground conditions

14.1 Introduction

14.2 General information on probe drilling and previous experiences in different countries

14.3 Melen water tunnel excavated under the Bosphorus in Istanbul

14.4 Methodology of predicting weak zones ahead in the Melen water tunnel

14.5 Kargi energy tunnel

14.6 Conclusions

References

15 Application of umbrella arch in the Kargi project

15.1 Introduction

15.2 General concept of umbrella arch and worldwide application

15.3 Methodology of using umbrella arch in the Kargi project

15.4 Criteria used for umbrella arch in the Kargi project and the results

15.5 Conclusions

References

16 Index

End User License Agreement

List of Tables

2 Geology of Turkey and Istanbul, expected problems, some cuttability characteristics of the rocks

Table 2.1 Some of the completed metro tunnels [4].

Table 2.2 Some of recent TBM applications in sewerage projects in Istanbul [4].

Table 2.3 Some of tunnels completed within Marmaray Project [4].

Table 2.4 Summary of geological formations in Istanbul.

Table 2.5 Physical and mechanical properties of rocks taken from Trakya formation [8].

Table 2.6 Physical and mechanical properties of rocks taken from Trakya formation [9].

Table 2.7 Physical and mechanical properties of the rocks taken from Kartal formation (Zone A) [8].

Table 2.8 Physical and mechanical properties of the rock samples taken from Kartal formation (zone B) [8].

Table 2.9 Physical and mechanical properties of the rock samples taken from Kurtköy formation [8].

Table 2.10 Physical and mechanical properties of the rocks taken from Kurtkoy formation [9].

Table 2.11 Physical and mechanical properties of the rocks from Dolayoba formation [8].

Table 2.12 Physical and mechanical properties of the rocks taken from Doloyaba formation [9].

Table 2.13 Physical and mechanical characteristics of the rocks from Gozdag formation [9].

Table 2.14 Physical and mechanical characteristics of rocks from Tuzla formation (clay stone-shale) [9].

Table 2.15 Rock physical and mechanical properties of the samples from Sultanbeyli formation [9].

Table 2.16 In situ Schmidt hammer test values and point load test values [13]

Table 2.17 Summary of unrelieved cutting tests in Arcose [14].

Table 2.18 Summary of unrelieved cutting tests in Doloyaba limestone [14].

Table 2.19 Summary of unrelieved cutting tests in Kartal limestone [14].

Table 2.20 Disc cutting test results in Trakya formation (siltstone) in unrelieved mode [14].

Table 2.21 Summary of relieved cutting tests in arcose [14].

Table 2.22 Summary of relieved cutting tests in Dolayoba limestone [14].

Table 2.23 Summary of relieved cutting tests in Kartal limestone [14].

Table 2.24 Disc cutting test results in Trakya formation (siltstone) in relived mode [14].

Table 2.25 Mechanical and physical properties of the rock samples subjected to rock cutting tests [14].

Table 2.26 Specifications of the Robbins 165-162/E1080 TBM [15].

Table 2.27 Comparison of predicted and measured TBM performance values [15].

Table 2.28 Geomechanical parameters of the two rock types used in laboratory tests [12].

Table 2.29 Summary of rock cutting tests in unrelieved and relieved mode in two different rock samples [12].

Table 2.30 Basic technical specifications of the TBM [12].

Table 2.31 Comparison of the machine parameters calculated after the full-scale cutting tests and manufacturer design values [12].

Table 2.32 TBM (open mode) field data parameters [12].

Table 2.33 Predicted and the field TBM performance values [12].

Table 2.34 Geomechanical parameters of the rock types used in laboratory tests [18].

Table 2.35 The actual and measured values of thrust force values [18].

Table 2.36 General characteristics of TBM used in Tarabya tunnel [18].

Table 2.37 Basic technical specifications of the TBM [19].

Table 2.38 Geomechanical parameters of Kirklareli formation with fossil [19].

Table 2.39 Summary of laboratory rock cutting tests with V-type disc in unrelieved and relieved mode [19].

Table 2.40 TBM field data parameters [19].

3 Difficult ground conditions dictating selection of TBM type in Istanbul

Table 3.1 Machine performance in Buyukada and Trakya formations [1].

Table 3.2 Machine downtime in Buyukada and Trakya formation [1].

Table 3.3 Specifications of the Robbins 165-162/E1080 TBM [4].

Table 3.4 Performance of the TBM in the Tuzla-Dragos tunnel [3].

Table 3.5 Rating for machine utilization (RMU) using double-shield TBM and wire mesh, shotcrete, steel arch and secondary lining system [3].

Table 3.6 Performance of TBM No. 5 in the Marmaray project.

Table 3.7 Basic technical specifications of the TBM [6].

4 Difficult ground conditions affecting performance of EPB-TBMs

Table 4.1 Description of tunnel projects with field and predicted specific energy values [3].

Table 4.2 Guidelines for estimating TBM utilization time [3, 4].

Table 4.3 Mean rock properties between two stations [5].

Table 4.4 Variation of specific energy values in Lines 1 and 2 (between shafts 8 and 7) with TBM penetration [5].

Table 4.5 Predicted and realized TBM Performance in Lines 2 and 1 between shafts 8 and 7 [5].

Table 4.6 Predicted and actual daily advance rates covering the period 12 February 2013 to 7 March 2015 [5].

Table 4.7 Variation of mean face pressure, optimum field specific energy and cutting power in different geological formations for the Mahmutbey–Umraniye metro tunnels [5].

5 Selection of cutter type for difficult ground conditions

Table 5.1 The summary of the cutting test results [2].

6 Effects of North and East Anatolian Faults on TBM performances

Table 6.1 Performance values of TBM and drill and blast excavations [2a, 2b].

Table 6.2 A TBM risk classification for tunnels to be excavated close to NAF and EAF [5].

7 Effect of blocky ground on TBM performance and the mechanism of rock rupture

Table 7.1 Basic technical specifications of the Herrenknecht TBM [4].

Table 7.2 Material consumption with TBM excavation in Lines 1 and 2 [3].

8 Effects of transition zones, dykes, fault zones and rock discontinuities on TBM performance

Table 8.1 General stratigraphy of the project area [1, 2, 3].

Table 8.2 Technical characteristics of the TBM [1].

Table 8.3 Mean values of TBM avances.

Table 8.4 The effect of geological formation on machine utilization time [2, 3].

Table 8.5 Some physical and mechanical properties of rock formations [5].

Table 8.6 Summary of TBM blockages in 11 different areas [5].

Table 8.7 TBM performance parameters related to face collapses and TBM blockage [6].

9 Squeezing grounds and their effects on TBM performance

Table 9.1 Characteristics of Herrenknecht EPB-TBM

Table 9.2 The performance of TBM in squeezing zones jamming the shield [2].

Table 9.3 Squeezing zones and Q values in Uluabat tunnel [25].

Table 9.4 Characteristics of seven areas where jamming of the TBM occurred [7].

Table 9.5 The chainage of the galleries, Q values and associated faults [25].

10 Clogging of the TBM cutterhead

Table 10.1 Physical and mechanical properties of rock formations [7].

11 Effect of high strength rocks on TBM performance

Table 11.1 Some of the properties of the rock masses [9].

Table 11.2 Technical features of Herrenknecht (M1801M) EPB-TBM.

12 Effect of high abrasivity on TBM performance

Table 12.1 Some parameters affecting cutter life, replacement and consumption rates for TBMs (revised from [1, 2]).

Table 12.2 Major cutter failure mechanisms [3, 4].

Table 12.3 Basic disc cutter damage types [5].

Table 12.4 Rock abrasivity classification based on Cerchar abrasivity index [9].

Table 12.5 Rock abrasivity classification based on Cerchar abrasivity index [10].

Table 12.6 Technical features of the EPB-TBM used in the Tuzla-Akfirat wastewater tunnel [23].

Table 12.7 Summary of excavation performance in the Tuzla-Akfirat wastewater tunnel [23].

Table 12.8 Some of the geological and geotechnical properties of the excavated zones including some operational parameters of the double-shield TBM in the Yamanli II HEPP tunnel [24].

Table 12.9 Technical features of the Robbins double-shield TBM used in the Yamanli II HEPP tunnel [24].

Table 12.10 Summary of excavation performance in the Yamanli II HEPP tunnel [24].

Table 12.11 Total cutter ring replacement numbers and rates, based on excavated rock mass zones in the Yamanli II HEPP tunnel [24].

Table 12.12 Number of cutter ring replacements based on cutter damage types and excavated rock mass zones in the Yamanli II HEPP tunnel [24].

Table 12.13 Physical and mechanical properties of the siltstone-claystone and diabase between Carsi and Umraniye stations [6].

Table 12.14 Some of the technical features of the EPB-TBMs used in the Uskudar–Umraniye–Cekmekoy–Sancaktepe metro tunnel [6].

Table 12.15 Excavation performance and some of the operational parameters realized during excavation of Lines 1 and 2 between Carsi and Umraniye stations [6].

Table 12.16 Cutter consumptions during excavation of Lines 1 and 2 between Carsi and Umraniye stations [6].

Table 12.17 Cutter wear damage types of the disc cutters for Lines 1 and 2 between Carsi and Umraniye stations [6].

13 Effect of methane and other gases on TBM performance

Table 13.1 Technical specifications of the Herrenknecht EPB-TBM.

Table 13.2 Record excavation performance in April 2011.

Table 13.3 Technical specifications of the Herrenknecht double-shield TBM used in the Silvan irrigation tunnel.

Table 13.4 Examples of gas-related accidents that occurred during tunneling.

14 Probe drilling ahead of TBMs in difficult ground conditions

Table 14.1 Compressive strength test results calculated after an NCB cone indenter test.

Table 14.2 The variation of normalized probe drilling rate with normalized TBM thrust.

Table 14.3 The variation of TBM thrust and torque with probe drill data obtained from histogram within different tunnel chainages representing different geological formations.

Table 14.4 Classification for difficulty in TBM excavations, based on mean values taken from frequency of variables.

Guide

Cover

Table of Contents

Begin Reading

Pages

C1

III

IV

V

VII

IX

XI

XIII

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

208

209

211

212

213

214

215

216

217

218

219

220

221

222

223

225

226

227

228

229

230

231

232

233

234

235

236

237

238

239

240

241

242

243

244

245

246

247

248

249

250

251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

268

269

270

271

272

273

274

275

276

277

278

279

280

281

282

283

284

285

286

287

288

289

290

291

292

293

294

295

296

297

298

299

300

301

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

319

321

322

323

324

325

326

327

328

329

330

331

332

333

334

335

336

TBM Excavation in Difficult Ground Conditions

Case Studies from Turkey

Nuh Bilgin

Hanifi Copur

Cemal Balci

Prof. Dr. Nuh BilginProf. Dr. Hanifi CopurProf. Dr. Cemal Balci

Istanbul Technical UniversityFaculty of Mines, Mining Engineering Department34469 Maslak/IstanbulTurkey

Cover: Methane Explosion in the Pressure Chamber of a Tunnel Boring MachinePhoto: Bilgin/Copur

Library of Congress Card No.:applied for

British Library Cataloguing-in-Publication DataA catalogue record for this book is available from the British Library.

Bibliographic information published by the Deutsche NationalbibliothekThe Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available on the Internet at <http://dnb.d-nb.de>.

© 2016 Wilhelm Ernst & Sohn, Verlag für Architektur und technischeWissenschaften GmbH & Co. KG, Rotherstraße 21, 10245 Berlin, Germany

All rights reserved (including those of translation into other languages). No part of this book may be reproduced in any form – by photoprinting, microfilm, or any other means – nor transmitted or translated into a machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law.

Print ISBN: 978-3-433-03150-6ePDF ISBN: 978-3-433-60722-0ePub ISBN: 978-3-433-60720-6eMobi ISBN: 978-3-433-60721-3oBook ISBN: 978-3-433-60719-0

This book is dedicated to our lovely wivesAyfer Bilgin, Nurten Copur and Nurgul Balciand our beloved childrenDamlanur Bilgin, Serkan and Busra Copur and Cem Eren Balci

Preface

The use of tunnel boring machine (TBM) tunneling has increased considerably in the past ten years in Turkey. It is planned to excavate 200 km of tunnels in the near future in Istanbul alone, and 100km of tunnels in other parts of Turkey. Thirty new TBMs are predicted to start working in Istanbul during 2017.

The geology of Turkey is complex, and the country is in a tectonically active region; on a broad scale, the tectonics of the region are controlled by the collision of the Arabian Plate and the Eurasian Plate. The Anatolian block is being squeezed to the west. The block is bounded to the north by the North Anatolian Fault and to the south-east by the East Anatolian Fault. The effects of these faults are seen clearly on the performance of TBMs used in these regions.

This book is written with the intention of sharing the tunneling experiences gained during several years in difficult ground and complex geology. The methane explosion in an earth pressure balance (EPB) TBM chamber, the clogging of a TBM, the need to change disc cutters to chisel cutters, the need to change CCS-type discs cutters to V-type disc cutters, excessive disc cutter consumption, the optimum selection of TBM type in complex geology, magmatic inclusions or ‘dykes’, the effect of blocky ground on TBM performance, the mechanism of rock rupture in front of TBMs, TBM face collapses and blockages, the effect of opening ratio in EPB-TBMs in fractured rock, squeezing of the TBM or jamming of the cutterhead, probe drilling and the use of umbrella arching ahead of TBMs are discussed within this book.