SHIELD TBM. The Advanced Tunneling Method

Transcription

1 The Advanced Tunneling Method HEAD OFFICE Guseo 2-dong, Guemjeongu, Busan,Korea Tel Fax SEOUL REGIONAL HEADQUARTERS 16th Floor, Seongwon Bldg, 141 Samseong-dong, Gangnam-gu Seoul Tel Fax INDIA CORPORATION #329, 3rd Floor, Tower-B, Spazedge, Sector-47, Gurgaon-Sohna Road, Gurgaon, Haryana , India Tel ~8 Fax ABU DHABI BRANCH OFFICE P.O.Box , Abu Dhabi, UAE Tel Fax BAHRAIN BRANCH OFFICE Office22, Entrance 892, Road3316, Manama/Ummal Hassam 0333,Capital Governorate,Bahrain Tel CAMBODIA BRANCH OFFICE IOC Center F4 R2, No. 254, Monivong Blvd, Sangkat Beong Raing, Khan Daun Penh, Phnom Penh City Tel VIETNAM CORPORATION A1/43 Building, 130 Doc Ngu, Ba Dinh District, HaNoi, Viet Nam Tel KUWAIT BRANCH OFFICE P.O.Box Safat Kuwait city-kuwait Tel FAX SINGAPORE BRANCH OFFICE 192 Waterloo Street #04-07 Skyline Bldg Singapore Tel Fax QATAR BRANCH OFFICE P.O. Box Doha, Qatar Tel Fax

2 Table of Contents 04 Introduction 05 Advantages and Factors Considered 06 EPB & Slurry TBM Operations 09 Quality Control 11 Cutter Head Design to Layer Type 12 Segment 15 Main Projects 24 Track Record 25 TBM Owned The Advanced Tunneling Method

3 Introduction Advantages and Factors Considered Advantages Minimize works on the ground besides both shafts for launch and arrival of shield TBM. Minimize noise, vibration, dust, pollution, etc. from construction. Minimize disturbance ~ Minimize diversion of existing underground facilities along tunnel alignment. The process is repetitive, so that most of the works can be automated and easily managed. A method of underground tunneling using Shield TBM (Tunnel Boring Machines) Compared to cut & cover method, the depth of tunnel has influence on the construction cost. Tunneling under river, sea, buildings, etc. is made easy compared to other methods of tunneling. It is possible to construct more curved and steep tunnel than other methods. Since many researches are still ongoing in the advancement of shield TBM, it is expected to be A method of tunnel excavation which avoids ground collapse and ground settlement. Subsequently after the excavation, segmented lining is installed from the rear part of the shield TBM. This method can prevent the collapse and settlement of the ground during excavation. 5 With excavating the ground, segmented lining is installed from the rear part of the shield TBM. Compared to the cut & cover method for excavation, this method is considered as much safer & eco-friendly method. Complexity of construction is less than cut & cover method. Less disturbance to surrounding structures & people, which implies suitability for down town tunnels. Factors Considered Additional counterplan such as ground improvement can be required to maintain the face pressure in control and prevent ground settlement if the soil cover of excavation section is thin. Wider working area can be required for shafts of launch and arrival compared to other methods. A lot of works at the shafts can cause construction pollution such as noise & vibration to surrounding circumstances. 4 applied under any ground conditions hereafter.

4 EPB & Slurry TBM Operations Earth Pressure Balanced (EPB) Shield Slurry Type Shield Travel path of excavated material. Travel path of excavated material Excavation Chamber Screw Conveyor The face pressure balance is maintained by the chamber pressure (open, closed mode of pressure gate) and by the screw conveyor operation (hauling speed). Bentonite or foam will be required to ease the flow of excavated material Belt Conveyor Disposal. Muck Pit Muck Car Excavation Chamber (mixed with slurry) Slurry type Excavation Disposal Slurry Discharge Pipe STP (Separation of soil & water) The slurry pressure is applied to cutting surface for maintaining the face pressure. The pressure wall also helps to maintain the face pressure in control. Be suitable for the ground such as loose sand, soft clay, and whose underground water level is high. Earth Pressure Balanced Shield Layout Slurry Shield Layout 6 1 Rear section working deck 2 3 Operating room Operating panel Advantages & Disadvantages of EPB Shield Oil tank unit Hydraulic pump unit Rear section working deck Tail seal greasing device Starter panel Slurry feeding pipe Operating panel Oil tank Transformer Segment Segment feeder Grease pump unit Hydraulic pump unit Slurry discharging pipe Advantages & Disadvantages of Slurry Type Shield 7 EPB Advantages Ease to identify the type of excavated material. Less space and facilities is required for site layout compared to slurry method. The disposal process of the material is simple compared to slurry method. Be possible to construct in clayey ground. Disadvantages Some additives are required to maintain earth balance in the loose ground condition. Be difficult to be applied in the ground whose underground water level is high. Slurry Advantages The face pressure balance is easily maintained by slurry in the unstable ground. Enable to be applied under various ground types. Working environment is clean within tunnel. Transporting the excavated material to the ground is easy and continuous transport is possible. Disadvantages More space and facilities is required for site layout compared to EPB method. Some additives are required for separating fine-grained soil.

5 EPB & Slurry TBM Operations Quality Control Construction Process 1 Shield skin gauge 2 This gauge, as an additional monitoring system, 3 is used to detect the following. Excavation diameter Time to replace roller bits. Presence of voids(air/water pockets). Shaft Construction TBM Assembly Initial Drive The cutter head interventions can be forecasted by checking the cutter wear. Through this gauge, it is possible to prevent unexpected interruptions such as sudden cutter head Slurry Type EPB Type Break Through intervention and precautionary measures can be carried out earlier if the voids are detected. Monitoring Volume of Excavated Material Over view 6 U Turn The monitoring is carried out to control amount of excavated material using the automatic 3D-laser scanning equipment which enables to monitor continuously & accurately. This monitoring makes it possible to prevent the ground settlement due to excessive excavation.

6 Quality Control Cutter Head Design to Layer Type Automatic Guidance System Soil Layer Site office Delete Cutter bit Shell bit Opening ratio of head is high. 10 Use of Automated System 11 It is possible to excavate with scraper & cutter bit without roller cutter. Installation of total station in tunnel. More frequent checks with the alignment. Real time monitoring in computerized display. Rock Layer Accurate alignment of tunnel drive. Roller cutter In TBM In TBM Total Station (Transit Point) Back RMT (Back Sight) Roller cutter is mainly used to excavate. Scraper helps to push the excavated material into the chamber. Sudden change of strata can cause side wear of roller cutter.

7 Segment Segment Types Segment Bolts Curved bolt 12 Straight bolt 13 Based on shape Segment (first lining) is Based on Key Segment Box type bolt Standard shape Installed by pushing upward With Taper Suitable for shield TBM of small diameter For curved sections For alignment control Installed by sliding from side Suitable for shield TBM of large diameter Soft fix type Quick joint type

8 Segment Main Projects Segment Production Singapore DTSS-Kim Chuan Link Sewer Drop Shaft C 2 1 Upper Paya Leber/PIE Interchange LEGEND MH-C1-1 (Receiving) KIM CHUAN LINK SEWERS Paya Lebar MRT DTSS TUNNEL MH-C1-3 (Launching) EXCAVATION DIRECTION EXISTING PUMPING STATION TEMPORARY SHAFT MH-C1-4 MH-C1-5 Fabricate rebar Install rebar in mould MH-C1-6 TANJONG RHU P.S. Curing in water MH-C1-10 MH-C1-12 MH-C1-9 MH-C1-8 MH-C1-7 (Receiving) 15 Fort Rd MH-C1-13 (Launching) Construction Period : 2002/5~2005/5 : Φ3,260mm : 5,200m : EPB 6 5 Remove mould & trim surface Ringwood Rd RINGWOOD P.S. MH-C1-14 ECP Casting MH-C1-10a MH-C1-15 (Receiving) d -12 -C1 MH 14 e -12 -C1 MH C1 a MH -12 -C1 MH b -12 -C1 c MH -12 -C1 MH Tanjong Rhu Rd : First oversea shield project, in Dongah Visual inspection

9 Main Projects Incheon Airport Rail Road Project Phase 2-5B Seoul Subway Line 9 Section No. 9 PARLIAMENT REC. SHAFT L=1,195m 914 STATION Phase 2-5B L=612m Susaek Seoul Hangdae 16 Kimpo GongDuk Construction Period : 2004/4~2009/12 : Φ7,930mm : 984m Construction Period : 2003/09~2009/08 : Φ7,810mm : 3,600m STATION : EPB : Shield skin gauge and monitoring volume of excavation : Slurry : Very close drive to bridge piers (As close to 50cm)

10 Main Projects Seoul Subway Section 704 Start Geoyeo Garak Power Cable Tunnel End Tunnel Construction Period : 2004/4~2009/5 : Φ4,550mm : 2,459m : EPB : Use of foam and shell bit Construction Period : 2004/12~2011/3 : Φ7,300mm : Up-bound 510m, Downward 694m : EPB : Open mode double shield

11 Main Projects Busan Nambu Interception Sewer Phase 01 Gas Pipeline Across Masan Bay Rec. Shaft Launch Shaft Steel / Mould Segments 20 : EPB(Mix soil condition) : Slurry : First slurry drive using steel segments in korea : First shield tunnel in Dongah Section Along Tunnel Alignment Rec. Shaft Launch Shaft Sea Marine Clay Weathered Rock Soft Rock Hard Rock Construction Period : 1991/11~1997/3 : Φ3,550mm : 5,903m 21 Construction Period : 1997/11~01/02 : Φ2,300mm : 1,354m

12 Main Projects Gas Pipeline Across Keum River Noksan Discharge Sewer Weathered Rock Tunnel Alignment Construction Period : 1999/12~2002/08 : Φ3,520mm : 1,587m : Slurry : First tunnel under river in Korea(1.5dia) Monthly Productivity : Slurry : Special shaft with D/W and hybird face(soft & rock) Section Along Tunnel Alignment Rec. Shaft Section Along Tunnel Alignment Launch Shaft Rec. Shaft Launch Shaft Sea 1.5D Silt Clay Sandy Silt Silt Clay Silt Sand Weathered Rock Soft Rock Hard Rock Construction Period : 1998/12~00/12 : Φ3,500mm : 1,112m

13 Track Record TBM Owned Overseas Korea Name of project Country Client Contract Period Tunnel Length (m) Tunnel /ID(mm) Detail of work Geological Features Manufacture Remark Name of project GE3 Project Submarine Tunnel(Shield) for Supplying Steam Name of client Gunjang energy Name of main contractor SK E&C etec E&C Contract Period Tunnel Length (m) Details of work Tunnel Geological /ID(mm) Features Remark Manufacture ~ ,000 3,236 Soft Rock Hard Rock RASA Slurry Yulchon II Combined Cycle Power Plant Meiya Yulchon Generation HYUNDAI E&C ~ ,560 3,800 Soil KAWASAKI EPB Down Town Line Contract 937 STEP Deep Tunnel Sewer Contract T-01 Singapore Abu Dhabi Land Transport Authority ADSSC ,450 ID(mm) 5,800 16,019 4,500 FCBB ROBBINS EPB Gymsum, Mud Stone, Silt Stone KAWASAKI EPB Olympic Dual Water Line Construction The Office of WaterworksSeoul Metropolitan Government CHUNHO E&C ~ ,426 2,200 Soft Rock Hard Rock RASA Slurry Seoul Subway Line 9 Section No.21 SMIH POSCO E&C ~ ,544 6,880 Soft Rock Hard Rock KAWASAKI EPB Seawater Desalination R&D Facility Construction Busan Water Authority Ultra C&E ~ ,050 Soft Rock Hard Rock KAWASAKI TBM Busan~Yeongdo area Electric Power Transmission Line KEPCO KUKDONG E&C ~ ,155 2,900 Soft Rock Hard Rock RASA Slurry Seoul Subway Line 9 Section No.20 Phase 3 SMIH LOTTE E&C ~ ,868 6,940 Mixed Face KAWASAKI EPB Kwangjin Jungnang area Electric Power Transmission Line KEPCO SAMHO ~ ,259 3,000 Weathered Rock KAWASAKI EPB Dobong District Electricity Power Transmission Line Project Korea Electric Power Co. Daelim Industry Co ~ ,700 3,000 Soft Rock, Hard Rock KAWASAKI EPB Kangnam Di s t r ic t Elec t r i c i tytransmission Line Project Korea Electric Power Co. SK E&C ~ ,289 3,000 Soft Rock, Hard Rock KAWASAKI EPB 24 Down Town Line Contract 913 Down Town Line Contract 915 DTSS Kimchuan Link Sewer C01 Singapore Singapore Singapore Land Transport Authority Land Transport Authority PUB ,475 5,800 4,330 5,800 Rock & Mixed Soil Rock & Mixed Soil KAWASAKI KAWASAKI Slurry Slurry 5,200 2,500 Soil LOVAT EPB Youngdong~Yangjae Telecommunication Line Project Korea Telecom Kukdong E&C ~ ,278 2,200 Soft Rock, Weatered Rock KAWASAKI Slurry Donggu District Electricity Power Transmission Line Project Korea Electric Power Co. Hyundai E&C ~ ,072 2,850 Soft Rock, Hard Rock KAWASAKI EPB New Sungnam 345KV Electric Power Transmission Line Project Korea Electric Power Co. Samho Co ~ ,297 3,800 Soft Rock, Hard Rock KAWASAKI EPB Gunsan Combined Power Plant Intake Tunnel Project Korea Western Power Co Samsung E&C ~ ,270 3,800 Soil KAWASAKI EPB Seoul Subway Line 7 Section 4 SEOUL Metropolitan City Samsung E&C ~ ,204 6,530 Weathered Soil HITACHI EPB Geyeo Cable~Garak Electricity Transmission Line Project Korea Electric Power Co. Daewoo E&C ~ ,455 3,800 Soft Rock, Hard Rock KAWASAKI EPB Incheon Airport Railroad Phase 2 Airport Railroad Co Shamhwan Co ~ ,935 6,880 Soft Rock, Hard Rock, Weatered Rock KAWASAKI EPB Seoul Subway Line 9 Section No.9 Public Procurement Service Doosan Inc ~ ,634 6,750 Mixed Face KAWASAKI Slurry Noksan Sewerage Treatment Plant Discharge Sewer Project PUSAN Metropolitan City Ssangyong Co ~ ,000 Soft Rock, Hard Rock KAWASAKI EPB New Ansan Substation Electricity Transmission Line Project Korea Electric Power Co. J.R E&C ~ ,850 Soft Rock, Moderated Rock KAWASAKI EPB Across Han River Telecommunication Line Project Korea Telecom Co. Kukdong E&C ~ ,910 2,200 Mixed Face RASA Slurry DTSS-Kim Chuan Link Sewer Project Singapore Public Utility Board Tiongseng /Dong-A JV ~ ,200 2,500 Marine Clay LOVAT EPB Daelim Substation Electricity Transmission Line Project Korea Electric Power Co. J.R E&C ~ ,672 2,850 Soft Rock, Hard Rock KAWASAKI EPB Siheung Doksan Electricity Transmission Line Project Korea Electric Power Co. SK E&C ~ ,746 2,850 Soft Rock, Hard Rock LOVAT EPB Noksan Discharge Sewer Project PUSAN Metropolitan City Ssangyong Co ~ ,587 3,000 Soil, Hard Rock RASA Slurry West Daejeon Telecom Office Telecommunication Line Korea Telecom Co. Jinro E&C ~ ,750 Weathered Rock LOVAT EPB North Suwon Telecom Office Telecommunication Line Project Korea Telecom Co. Samho Co ,750 Weathered Rock LOVAT EPB 25 Across Keum River Gas Pipe Line Project Korea Gas Co. Hyundai E&C ~ ,113 3,050 Soil RASA EPB Across Masan Bay Gas Pipe Line Project Korea Gas Co. Korea Heavy Industry Co ~ ,354 1,850 Soft Rock KAWASAKI Slurry Masan City 154KV Electricity Transmission Line Project Korea Electric Power Co. Korea Heavy Industry Co ~ ,330 2,850 Mixed Face Herenknecht Slurry Pusan Nambu Sewerage Treatment Plant Discharge Sewer Project PUSAN Metropolitan City Backil E&C ~ ,600 Hard Rock KAWASAKI EPB Eumgung 154KV Electricity Transmission Line Project Korea Electric Power Co. Kukje E&C ~ ,800 Clay, Sand KAWASAKI EPB Ansan City Telecom Office Telecommunication Line Project Korea Telecom Co. Kukje E&C ~ ,750 Mixed Face LOVAT EPB Pusan Nambu Sewerage Treatment Plant Link Sewer Project PUSAN Metropolitan City Daewoo E&C ~ ,903 3,050 Clay, Hard Rock KAWASAKI EPB

14 TBM Owned D 4,340mm D 7,810mm KAWASAKI (Japan) KAWASAKI (Japan) Type of TBM EPB Type of TBM SLURRY Length of Shield 6,065mm Length of Shield 10,300mm Strata Type Soil, Weathered Rock & Soft Rock Strata Type Mixed Soil(Sand, Aggregate, Rock) 1.32 rpm, 2,000 ton 3 rpm, 5,600 ton 150 R 500 R D 3,520mm RASA (Japan) Type of TBM SLURRY Length of Shield 7,510mm 26 D 7,913mm KAWASAKI (Japan) Strata Type Soil, Weathered Rock & Soft, Hard Rock 4 rpm, 960 ton Type of TBM EPB 150 R Length of Shield 8,800mm D 2,750mm RASA (Japan) Strata Type Completely Weathered Rock, Slightly weathered rock & Rock (Hard &soft) 3 rpm, 5,600 ton 500 R 27 Type of TBM SLURRY Length of Shield 10,130mm Strata Type Soil, Weathered Rock, Soft, Hard Rock 9.8 rpm, 1,200 ton 300 R D 3,550mm KAWASAKI (Japan) Type of TBM EPB (Double) Length of Shield 10,300mm Strata Type Rock 7.6 rpm, 800 ton 150 R D 4,550mm KAWASAKI (Japan) Type of TBM EPB (Double) Length of Shield 11,100mm Strata Type Rock 7 rpm, 1,524 ton 300 R D 7,420mm D 3,600mm NKK (Japan) KAWASAKI (Japan) Type of TBM EPB Type of TBM EPB Length of Shield 8,330mm Length of Shield 6,065mm Strata Type Completely Weathered Rock & Slightly weathered rock Strata Type Soil & Weathered Rock & Soft Rock 2.5 rpm, 5,040 ton 9 rpm, 980 ton 200 R 80 R