7.

0 TUNNELING EQUIPMENT:

Tunneling equipment is a machine used to excavate tunnels with a

circular cross section through a variety of soil and rock strata. There can
bore through hard rock, sand and almost anything in between. Tunnel
diameters can range from a meter (done with micro-TBMs) to almost 16
meters. Tunnels of less than a meter or so in diameter are typically done
using trenchless construction methods or horizontal directional drilling.

Tunneling equipment has limiting disturbance to the surrounding

ground and producing a smooth tunnel wall. This significantly reduces
the cost of lining the tunnel and makes them suitable to use in heavy
urbanized areas. The major disadvantage is the upfront cost. TBMs are
expensive to construct and can be difficult to transport. However, as
modern tunnels become longer, the cost of tunnel boring machines
versus drill and blast is actually less-this is because tunneling with
TBMs is much more efficient and results in a shorter project period.

Type of tunneling equipment:

1. Auger boring machine

2. Gripper tunnel boring machine

3. Double shield tunnel boring machine

4. Single shield tunnel boring machine

5. Earth pressure balance tunnel boring machine

6. Microtunneling boring machine

7. Slurry pressure balance tunnel boring machine

8. Mixshield tunnel boring machine (TBM) Aker Wirth

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1. Auger Boring Machine

An Auger Boring Machine (ABM) is used to bore horizontally through soil

or rock with a cutting head and auger. The majority of ABMs are used to
install pipe casing under railroads, highways, airport runways, creeks or
any area of ground that cannot be open cut or disturbed in any way.

There are many types of cutting attachments for this machine. They
range from Backhoe Teeth cutters for cutting through soil to the Small
Boring Unit for boring hard rock.

Initially the ABM is set up in the starting pit on a predetermined length

of track. A backing plate, usually steel or reinforced concrete block, is
installed in the wall opposite of the boring to withstand the thrust
exerted by the boring machine. The machine bores through the earth
with a cutting head and the jacking force is provided by the hydraulic
thrust. The pipe casing and auger sections are added as the machine
advances. Spoil is removed from the auger through the casing to a door
located on the side of the machine.

Fig. 1 Auger Boring Machine

2. Gripper Tunnel Boring Machine (TBM)

Main Beam of TBM is complex in its design, yet relatively simple in

concept. The front of the TBM is a rotating cutter head that matches the
diameter of the tunnel. The cutter head holds disc cutters (ranging from
11" to 20" in diameter) which are positioned for optimal boring of the
given rock type. As the cutter head turns, hydraulic propel cylinders
push the cutters into the rock. The transfer of this high thrust through

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 the rolling disc cutters creates fractures in the rock causing chips to
break away from the tunnel face. A unique floating gripper system
pushes on the sidewalls and is locked in place while the propel cylinders
extend, allowing the main beam to advance the TBM. The machine can
be continuously steered while gripper shoes push on the sidewalls to
react the machine's forward thrust. Buckets in the rotating cutter head
scoop up and deposit the muck on to a belt conveyor inside the main
beam. The muck is then transferred to the rear of the machine for
removal from the tunnel. At the end of a stroke the rear legs of the
machine are lowered, the grippers and propel cylinders are retracted. The
retraction of the propel cylinders repositions the gripper assembly for the
next boring cycle. The grippers are extended, the rear legs lifted, and
boring begins again.

Fig. 2 Gripper Tunnel Boring Machine

3. Double Shield Tunnel Boring Machine (TBM)

A Double Shield TBM consists of a rotating cutter head mounted to the

cutter head support followed by three shields: a telescopic shield (a
smaller diameter inner shield which slides within the larger outer shield),
a gripper shield and a tail shield.

In normal operation ("double shield mode"), the gripper shoes are

energized, pushing against the tunnel walls to react the boring forces.
The main propel cylinders are then extended to push the cutter head
support and cutter head forward. The rotating cutter head cuts the rock.
The telescopic shield extends as the machine advances keeping
everything in the machine under cover and protected from the ground
surrounding it.

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 The gripper shield remains stationary during boring. A segment erector is
fixed to the gripper shield allowing pre-cast concrete tunnel lining
segments to be erected while the machine is boring. The segments are
erected within the safety of the tail shield. It is the Double Shield's ability
to erect the tunnel lining simultaneously with boring that allows it to
achieve such high performance rates. The completely enclosed shielded
design provides the safe working environment.

If the ground becomes too weak to support the gripper shoe pressure, the
machine thrust must be reacted another way. In this situation, the
machine can be operated in "single shield mode". Auxiliary thrust
cylinders are located in the gripper shield. In single shield mode they
transfer the thrust from the gripper shield to the tunnel lining. Since the
thrust is transferred to the tunnel lining, it is not possible to erect the
lining simultaneously with boring. In the single shield mode, tunnel
boring and tunnel lining erection are sequential operations.

Regardless of the operating mode, working crews remain protected within

the shields. Double Shield TBMs are capable of safely excavating a wide
range of geologic conditions on a project. Double Shield TBMs are
manufactured to suit project requirements, in diameters from 1.6 m to
15 m (5 to 50 ft).

Fig. 3 Double Shield Tunnel Boring Machine

4. Single Shield Tunnel Boring Machine (TBM)

Single Shield TBMs protect workers from broken rock until the tunnel
lining can be safely installed. The body of the machine is enclosed in a
shield that is marginally smaller than the diameter of the tunnel. The
flat, low-profile cutter head minimizes disturbance of the face as it bores
and prevents large blocks from collapsing and causing excessive boring
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 stresses. The front of the TBM is a rotating cutter head that matches the
diameter of the tunnel. As the cutter head turns, a ring of hydraulic
cylinders provides forward thrust through shoes that push against the
tunnel lining.

The cutter head holds disc cutters (ranging from 11" to 20" in diameter)
positioned for optimal boring. The transfer of high thrust through the
rolling disc cutters creates fractures in the rock, causing chips to break
away from the face. Boring and lining installation are performed
sequentially. To steer, cylinders orient the articulated cutter head in the
required direction.

Single Shield TBMs are available in diameters from 1.6 to 15 m (5 to 50

ft). All Single Shields are equipped with high-speed segment erectors for
rapid tunnel lining installation. To steer the machine, the cutter head is
articulated. The short shield length enables a small turning radius and
minimizes exposure to squeezing ground forces that could potentially
trap the machine.

Fig. 4 Single Shield Tunnel Boring Machine

5. Earth Pressure Balance Tunnel Boring Machine (EPB TBM )

If the geology ranges from soft soils to weathered rock, then Earth
Pressure Balance Machine (EPBM) is the correct technical solution for
project. This is particularly true when project is located in an urban
environment and ground surface subsidence cannot be tolerated.

EPBMs are utilized in the construction of rail tunnels, metropolitan

subway systems, highway tunnels, and other projects where the tunnel
will be constructed either partly or completely in soft soil beneath the
water table.

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 From "Smooth Flow" cutter heads that reduce friction to super-reliable
sealing systems and Variable Frequency Cutter head Drives, has taken
the traditional EPB design to the next level.

Fig. 5 Earth Pressure Balance Tunnel Boring Machine

6.Microtunneling Boring Machine (MTBM)

Small Boring Units (SBU-A) is a small diameter rock cutting head (from
24"/600 mm to 72"/1.8 m) that can be used with any Auger Boring
Machine (ABM) to excavate hard rock on drives less than 500 ft (150 m).
SBU-A has been proven on hundreds of jobs across the U.S. Over one
hundred contractors in locations around the world have proven the SBU-
A works better than any other method of excavating small diameter, hard
rock bores.

Motorized Small Boring Units (SBU-Ms) is used to bore a small diameter

tunnel in hard rock where line and grade are critical. These machines
have been specifically designed for long bores (over 500 ft/150 m) with
difficult ground conditions. They are offered in cutter head diameters
from 48"/1.2 m to 78"/2.0 m.

Rock head (SBU-RHSS or SBU-RHDS)

If line and grade are critical and have a longer bore (over 1000 ft/300 m
in length) for project, than Robbins Rock head is used. The diameter
range is available between 54" (1.35 m) and 78" (2.0 m). The Robbins
Rock head is a powerful mid-sized tunneling machine available in both
Single Shield and Double Shield models.

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 Fig. 6 Microtunneling Boring Machine

7. Slurry Pressure Balance Tunnel Boring Machine (SPB TBM)

Bentonite slurry, consisting of a specific clay and water mixture is

universally used in boring and digging operations. The slurry has
numerous properties: sealing of the cutting face, reduced friction on the
TBM's structure and transport of cuttings to the separation plant outside
the tunnel.

The basic principle of this TBM is to maintain the tunnel's cutting face
during the excavation phase by filling the working chamber, located
behind the cutter head, with slurry.

Slurry pressure is carefully controlled by a large air bubble which is

maintained by a separately-controlled air supply system. This air bubble
acts as a damper by absorbing sudden variations in mucking output.

Fig. 7 Slurry Pressure Balance Tunnel Boring Machine

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8. Mix shield Tunnel Boring Machine (TBM) Aker Wirth

Dual mode - two process technologies in one As the term 'dual mode'
indicates, two process technologies are combined in these machines.

Shield machines:

These machines are externally similar to shield machines and combine

the functional features of a hard-rock shield tunnel boring machine and
optionally, of a slurry shield or a hydro shield machine. They are always
used when tunnels have to be driven alternately in stable and unstable
sections.

New style machines:

Dual-mode tunnel boring machines are still a new type of machines and
have been developed to meet the requirements of complex projects in
strongly varying geologies. Where conventional tunneling techniques had
to be used formerly, these machines now open the way to lower-risk and
lower-cost tunneling in difficult geological conditions

Fig. 8 Mix shield Tunnel Boring Machine

Contacts:
1. www.robbinstbm.com
2. www.csmbessac.com
3. www.akersolutions.com/akerwirth
4. www.bemlindia.com
5. www.hitachizosen.co.jp

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