TUNNEL BORING MACHINES IN DIFFICULT GROUNDS...
Transcript of TUNNEL BORING MACHINES IN DIFFICULT GROUNDS...
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A UNIQUE PROJECT UNDER VARIABLEGEOLOGICAL AND WORKING CONDITIONS: EURASIA TUNNEL
16 November 2016Steigenberger Hotel, Maslak - Istanbul, Turkey
Dr. Eng. Burak GÖKÇEYapı Merkezi
Prof. Dr. Eng. Ergin ARIOĞLUYapı Merkezi
Dipl. Eng. Başar ARIOĞLUYapı Merkezi
TUNNEL BORING MACHINES IN DIFFICULT GROUNDSTURKISH TUNNELLING SOCIETY
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CAUTION
This presentation is prepared by:
Prof. Dr. Eng. Ergin ARIOĞLU - Yapı Merkezi R&D Department
Dipl. Eng. Başar ARIOĞLU - Yapı Merkezi İnşaat A.Ş.
Dr. Eng. H. Burak GÖKÇE - Yapı Merkezi R&D Department
In this report the remarks, evaluations made and conclusion drawn, that are under
progress, do not reflect the opinions of Yapı Merkezi Construction and Industry Inc. No
liability for negligence or otherwise can be accepted by Yapı Merkezi.
© 2016 Yapı Merkezi Construction and Industry Inc. All Rights Reserved. Except as
otherwise permitted by Yapı Merkezi Construction and Industry Inc., this publication, or
parts thereof, may not be reproduced in any form, by any method, for any purpose.
http://www.ym.com.tr/
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Trakya Formation
Marmara Sea
CONTENT
Source: ATAŞ (2014)
Project in Brief
Seismicity
Geology
Geotechnics
Tunnel Boring Machine
Advance Rates
Standstills
Excavation Parameters
Conclusions
Acknowledgements
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PROJECT IN BRIEF
Model: Build – Operate – TransferTotal Investment: ~1,3 Billion $Construction Period: 55 Months
• Road and tunnel structuresOperation Period: ~ 26 Years
Total Project Length: 14.6 km
•Part-1: Europe side (5,4 km)
•Part-2: Bosphorus Crossing (5,4 km)
•Part-3: Asia side (3,8 km)
1st and 2nd bridges (total 7x2 lanes)• 180.000 (1st) and 220.000 (2nd) crossings
per dayEurasia Tunnel (2x2 lanes)• 110.000 crossings per day (both directions)
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GUARANTOR Republic of Turkey Prime MinistryUndersecretariat of Treasury
SPECIAL PURPOSE COMPANY Eurasia Tunnel Operation Const. & Invest. Inc.
OPERATOR EGIS Tunnel Operation Co.
TBM MANUFACTURER Herrenknecht AG
CONSTRUCTION COMPANY (EPC JV)YMSK Joint Venture
OWNER
INVESTOR / CONTRACTOR
Ministry of Transportation
General Directorate of Infrastructure Investments
Yapı Merkezi Construction Inc.
SK Engineering & Construction Company Ltd.
DESIGNER
INDEPENDENT DESIGN VERIFIER HNTB Corporation
Parsons Brinckerhoff
REINSURANCE & INSURANCEMunich RE
Zurich RESEGMENT PRODUCER
Yapı Merkezi Prefabrication Inc.
ADVISORSSUBJECT
TRAFFIC
ENVIRONMENTAL & SOCIAL
INSURANCE
LEGAL
FINANCETAX
Jacobs Engineering Group
ERM Environmental Resources Mangt.
Marsh Insurance Ltd.
Hergüner Attorney Partnership
Skadden LLP
UniCredit GroupPricewaterhouseCoopers
Arup Group Ltd..
JLT Jardine Lloyd Thompson Group
Fidan & Fidan Law Firm
Clifford Chance LLP
PricewaterhouseCoopers
Arup Group Ltd.
SPONSORS’ ADVISORS LENDERS’ ADVISORS
PROJECT PARTIES
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PROJECT CHRONOLOGY
Tender
City Plan Approval
TBM factory acceptance
Signing of IC
Ground-breaking Ceremony
Financial Close &
Commencing Construction
IC in effect & Asian Work Site Hand-over
Signing of Finance Agreements
STP Delivery to site accomplished
TBM at Site
Due Diligence Process Design & Construction
Initialing of IC
TBMLaunching
TBMBreakthrough
Pre & Detailed
FeasibilityStudy
ConstructionCompletion
Design
OperationCompletion
OperationTender
YM R&D YM R&D InternalInternal
Presentation
Source: ATAŞ (2016)
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SUCCESSFUL SUBSEA TUNNELLING UNDER BOSPHORUS: MELEN PROJECT
Contractor: STFA + Mosmetrostoy ve Türk ALKE
Project Cost: ~120 milyon US$
Tunnel Length: 5,5 km
EPB-TBM Diameter: 6,15 m -operated in open mode-with "0" face pressure
Minimum Rock Cover Thickness: 35 m
Maximum Depth TBM Tunnel: 135 m (70m-sea)
Formasyon: Dolayoba/Kartal formation
Clayey limestone, limestone-shale, sandstone, GSI: 45-64 (subsea section), several dykes (andesite/diabase) with 1-70 m thickness
Started in March-2008 and finished in April-2009 (one month earlier than planned)
Source: Anagnostou (2010) and Bakır et al. (2011)
Avrupa Avrupa Yakası Anadolu Anadolu
Yakası
Ölçeksiz
Sarıyer Beykoz
SECTION EXCAVATED WITH A TBM (3,4 km) SECTION EXCAVATED BY DRILL&BLAST
Alüvyon
Deepest Point of TBM Tunnel Source: Modified from Gerek et al. (2010)
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MAIN CHANGES OF EURASIA TUNNEL AFTER FIELD INVES.&PRELIMINARY STUDIES
Parameters Tender Documents Changes
Tunnel Diameter (m) 12.5 13.2
Tunnel Alignment Depth (m) -88.0 -106.4
Tunnel Gradient (%) 4.0 5.0
Face Support Pressure (bar) 9.0 11.0
Toll PlaceFor both traffic direction: European side
Asian-European direction:Asian side
European-Asian direction:European side
Geotechnical Parameters Based on Marmaray Project (there is a distance about 1.5 km)
Detailed desk/field and laboratoryinvestigations, structucture of seabottom markedly changes
Seismic Parameters General AssumptionsDetailed geophjysical studies andprobabilistic earthquakeapproaches
TBM Excavation Launch Method Deep shafts at European side Transition box at Asian side
Approaching Tunnels at Asian sideTunnel with variable-larger crosssections
Constant cross section
Eurasia tunnel Project with actual parameters is an unique Project in the World tunnel literature.
Source: ATAŞ (2011)
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SEISMICALLY ACTIVE FAULT SEGMENTS IN THE MARMARA REGION
Fault segment EarthquakeS7, S8 10/9/1509 (Ms = 7.2)S9 10/5/1556 (Ms = 7.2)S2, S3, S4, S5 25/5/1719 (Ms = 7.4)S6 2/9/1754 (Ms = 6.8)S7, S8 22/5/1766 (Ms = 7.1)S11 5/8/1766 (Ms = 7.4)S3, S4, S5 10/7/1894 (Ms = 7.3)S11 9/8/1912 (Ms = 7.3)S1, S2, S3, S4 17/8/1999 (Ms = 7.8)
Fault Segment Last Earthquake Median Recurrence TimeS1 12/11/1999(Ms = 7.3) -S2 17/8/1999 (Ms = 7.8) 140 :± 35 years S3 17/8/1999 (Ms = 7.8) 140 :± 35 years S4 17/8/1999 (Ms = 7.8) 140 :± 35 years S5 10/7/1894 (Ms = 7.3) 175 yearsS6 2/9/1754 (Ms = 6.8) 210 :± 40 yearsS7 22/5/1766 (Ms = 7.1) 250 yearsS8 22/5/1766 (Ms = 7.1) 250 yearsS9 10/5/1556 (Ms = 7.2) 200 :± 50 years S10 - 200 :± 50 years S11 9/8/1912 (Ms = 7.3) 150 years
Major Earthquakes (Ms > 6) Median Recurrence Times of Fault Segments
Source: Erdik (2004) and Wang et al. (2005)
Eurasia Tunnel
North Anatolian Fault Zone
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SEISMIC JOINTS
Shearr ±±±±±±±± 50 mm
Source: Modified from YMSK Joint Venture (2014)
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According to geological/geophysical studies (based on borehole logs and seismic refraction)
Asia Side Full face Trakya Formation with different joint, stiffness
and abrasiveness (sandstone, mudstone, dykes) ≈ 564 m
Asia Mixed face (weak and weathered rock mass and marine sediments) ≈ 112 m
Marine sediments (sandy / clayey soil) ≈ 752 m
Europe Mixed face ≈ 112 m
Europe Side Full face Trakya Formation ≈ 1800 m
TBM TUNNEL GEOLOGY OF EURASIA TUNNEL
Source: Yapı Merkezi Visual Design (2014)
LITOLOGY(Between Ring No: 0 - 1627)
Length (m)
Volcanic Dykes 413Fault & Crushed Zone 101
Source: Bakır, Aydın (2015)
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Geological Strength Index (Cai et al. 2004)
Block Volume
Joint Condition Factor (Palmstrom, 1995)
ROCK MASS CHARACTERIZATION IN TRAKYA FORMATIONRange of Block Volume -gravel sized-
Wor
seni
ngJo
intC
ondi
tions
Block Volume becomes extremely small size
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Expected GSI Values(shaded area)
Rock mass unit
Rock mass structure description
Joint/Block wall surface condition
GSIJoint sets
Joint spacingS (cm)
Block Volume, Vb
(cm3)Description
Joint condition factor, Jc
Typical blocky sandstone 3 30-100 2.7x104-106 Rough slightly weathered 1.7 – 4.5 55 - 75
Very blocky sandstone withmudstone/siltstone
3 or 4 10-30 103-2.7x104 Rough slightly weathered 1.7 – 4.5 45 - 65
Mudstone/siltstone with sandstone layers
4 10-30 103-2.7x104 Smooth, moderately weathered/altered surface
0.67 – 1.7 35 - 55
Tectonically disturbed, folded, faulted zones
> 4 3-10 27-1000Slickenslided variable weathered surfaces
0.25 – 0.67 20 - 35
Disintegrated completely crushed rock: translation
- < 3 <27Slickenslided highly weathered surface with clay coatings
0.1 – 0.25 < 20
Note: “Jw” stands for large-scale waviness and “Js”stands for small-scale smoothness. S1, S2, S3 arespacings between the individual joints in each setand γ1, γ 2, γ 3 are the angles between the joint sets.
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VARIATION OF UNIAXIAL COMPRESSIVE STRENGTH WITH DEPTH
Source: Yapı Merkezi R&D (2010)
= mean values = standard deviationV = coefficient of variation (%),
V = s / x100
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GENERAL OUTLOOK ON MARINE SEDIMENTS
Properties of marine sediments based on cone penetration test (CPT) and measured shear wavevelocity from P/S logging.
Marine sediments (Holecene aged, 7400 ± 1300) varies from coarse-grained soils (gravels and sand) to finegrained soils (silts and clays) and change both vertically and laterally as a result of sedimental regime.
The coarse-grained soils (usually silty/clayey fine sand) are dense. The sands own high stiffness under highconfining pressure.
Generally speaking, the marine sediments that are normally to lightly overconsolidated at the tunnel axisdepth and consist of inter-bedded sands, silts and clay. The soils appear to be normally consolidated i.e.OCR≈1, many design properties (undrained shear strength -cohesion value-, stiffness) enhance with depth.
Undrained shear strength can be approximated as:
Undrained elastic modulus at 50 % peak deviation stress (E50) can be correlated with cu value
As for the effective internal friction angle ( ) for sandy soils can be estimated from the modified equation(Kulhawy and Mayne, 1990):
Some carbonates due to shell of micro/macro organisms are observed throughout the depth of soils upto 35% CaCO3 at (mean value 25%) Project site. These carbonates were believed in increase "liquefactionresistance" of sandy soils during seismic loading owing to their roughness structure and reduce inabrasion.
(σv' = effective vertical pressure; γ'=submerged unit weight; z = depth from sea bottom surface)
(qc= measured cone tip resistance in MPa; z = depth from sea bottom surface in meters)
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PREDICTED AND MEASURED EFFECTIVE INTERNAL FRICTION ANGLE
Note: Robertson (2009) was used for predicted values. Xm = mean value, Xk(1) = characteristicvalue based on student value method, , Xk(2) = characteristic value based on Schneider's method. Source: Yapı Merkezi R&D Department, 2010©
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BOREHOLE BH1-5
Source: Yapı Merkezi R&D (2012)
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SOME ILLUSTRATIVE EXAMPLES OF BOREHOLES
Source: Yapı Merkezi Design and R&D Departments (2010)
BHJ-5 (ASIA SIDE TRANSITION ZONE)BHJ-1 (EUROPE SIDE)0 m
10 m
20 m
30 m
40 m
50 m
60 m
0 m
10 m
20 m
30 m
40 m
50 m
60 m
Sand
Clayey Silty Sand
Mudstone
Sandstone
Mudstone
Diabase
Diabase
Mudstone
Sandstone
Mudstone
0 m
10 m
20 m
30 m
40 m
50 m
60 m
70 m
80 m
90 m
100 m
110 m
Clayey Silty SandSandy Clay Silt
Clayey Silty Sand
Sandy Clay Silt
Sandy Clay Silt
Sand
0 m
10 m
20 m
30 m
40 m
50 m
Clayey Silty Sand
60 m
70 m
Sandy Clay SiltSandSandy Clay Silt
Sand
SandstoneMudstoneSandstone
Mudstone
Sandstone
0 m
10 m
20 m
30 m
40 m
50 m
60 m
70 m
80 m
90 m
0 m
10 m
20 m
30 m
40 m
50 m
60 m
70 m
Sand
Clayey Silty Sand
GravelSandMudstone
Sandstone
BHJ-1 BH1-4 BHJ-5
BH1-4
Source: Bakır, Aydın (2015)
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Source: YMSK Joint Venture (2015)
EXISTENCE OF DYKE ZONES
In Trakya Formation, Sandstone/Mudstone layers cut through dykes (andesite and diabase).
Such a geological setting creates a different rock mass medium with variable stiffness.
Andesite/Diabase dykes have uniaxial compressive strengths more than 200 MPa.
Cherchar Abrasive Index (CAI) is an indication of cutter disc/tools wear rate and in the case
of dykes, this index increases up to 4.5 (extremely abrasive).
Pinkk color in geological profile below corresponds to dyke zones faced during excavation.
Parameter Asia Side Trakya Formation
Europe Side Trakya Formation Overall Trakya Formation
Number of Dyke Zone 6 23 29
Total Dyke Length (m) 28 397 425
Average Dyke Length (m) 5 17 15
Average Dyke Frequency (m) 113 83 90Source: YMSK Joint Venture (2015)Note: Longest dyke's length is 120.0 m.
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FACE SUPPORT PRESSURE
"Slurry Pressure: Under the expected conditions, up to 10 bar high slurry pressures
will be necessary for operation in soft ground. This figure is higher than the highest
slurry pressures applied ever worldwide (7 bar) and means "unexplored terrority"
with respect to TBM design and TBM operation."
Quoted from "Istanbul Strait Road Crossing - Expert Panel Opinions on TBM
Type and Operation Report", page 1, 7 September 2009.
by
Prof. Dr. George ANAGNOSTOU
Prof. Dr. Nuh BILGIN
Prof. Dr. Levent OZDEMIR
Prof. Dr. Markus THEWES
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ESTIMATION OF FACE SUPPORT PRESSURE
0 m
10 m
20 m
30 m
40 m
50 m
60 m
70 m
80 m
90 m
100 m
110 m
0 m
10 m
20 m
30 m
40 m
50 m
Sand
Clayey Silty Sand
Mudstone
Sandy Clay-Silt
Marmara Sea
Face support pressure -at tunnel axis- based on soil/rockmechanic principles:
Horizontal earth pressureHydrostatic water pressure
Expected maximum effective vertical load on shield-neglecting arching effect-:
Mean value of lateral earth coefficient at rest and active state
= Effective internal friction of soil/weak rockmass, 30o -on conservative side-
Face support pressure -at tunnel axis-
TBM was designed on face support pressure of 12 bar.
(Tunnel diameter, D = 13.7 m; submerged unit weight of geomaterial, γ'=0.9t/m3)
(water depth, Hw=62 m; overburden thickness, H=26 m; unit weight of water, γw=1t/m3)
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DISCUSSIONS ON "SAFE HEAVENS" BY MEANS OF GROUND IMPROVEMENT OR
HPERBARIC OPERATIONS IN SUBSEA TUNNELRelationship between face support pressure and cohesion of geomaterial for subsea tunnelconditions for given critical geometric and working conditions, the following relationshipshown in figure can be set up:
Undrained cohesion value of weak, heavily jointed,weathered geomaterial can be estimated from thefollowing semi-empirical equation:
For the rock mass under consideration, internalfriction angle (φ = 15o – 30o), the arithmetic mean
value of can be assumed to be about 0.67,then the above equation is approximated as:
Uniaxial comp. strength of rock mass, = 2.5 MPa
Rock Quality Designation, = 0%
Joint Condition, = 5
Face
Supp
ortP
ress
ure,
Pf
Undrainedcohesion of Geomaterial, c
entirely crushedrock mass
Pf = 3.5 bar withcompressed air
Hyp
erba
ricO
pera
tion
when groundimprovementis applied
If c < com; cohesionvalue correspondingto no face pressurei.e open mode
com
closed mode
Hw
Ho
D Pf
Tunnel
σcm
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DISCUSSIONS ON "SAFE HEAVENS" BY MEANS OF GROUND IMPROVEMENT OR
HPERBARIC OPERATIONS IN SUBSEA TUNNEL
Then, for given conditions, the cohesion value can be calculated as:
Under extreme condition, say, entirely crushed rock mass due to intense tectonic events:
To sum up:
TBM will work in close mode for the stability of excavation face.
To eliminate hyperbaric operations, the long standstill for repair/maintenance of TBM isneeded "safe heavens" by means of ground improvements (deep mix method from sea watersurface, chemical/cementitious injections from inside of TBM, excavation of small diameter of pilottunnel from land side, freezing, jet grouting, etc.) can be applied.
No example Project for ground improvement is present under very high pressure such as11 bar -unmanagable pressure-
Hyperbaric diving is a preferable solution. Hence, the hyperbaric operations with mixedgas for short term standstills (inspection) and saturation for long term standstills(unplanned/planned maintenance + repair works) were adopted in the Project.
Source: Yapı Merkezi R&D (2013)
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TUNNEL AND TBM
TU
NN
EL
TBM Tunnel LengthTBM Tunnel Grade
3,340 m± 5%
TB
M -
GE
NE
RA
L Maximum Face PressureTBM DiameterLength of the TBM Weight of the TBMInstalled Total PowerNominal TorqueThrust Force
12 bar13.7 m120.0 m~3,300 t10,330 kW23,289 kNm247,300 kN
TB
M–
SP
EC
IAL
E
QU
IPM
EN
T
Φ2000mm Man LockΦ1600mm Center LockMaterial LockShuttle (3200 x 1600 x 1600 mm)
2 units2 units3 units1 unit
CU
TT
ING
TO
OL
S
Number of Total Disc Cutters Diameter of Disc CuttersSpacing (gauge / center disc cutters)
Atmospheric Changeable Cutting KniveHyperbaric Changeable Cutting Knive
35 (double)
19 inch100mm/120mm48144
SE
GM
EN
TS
Outer Ring DiameterInner Ring DiameterRing ArrangementSegment LengthSegment ThicknessWeight of a Complete Ring
13.2 m12.0 m8+1 keystone2000 mm600 mm127 t Mixix-x-Shieldd Slurryy Tunnelel Boringg Machine
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TUNNEL SEGMENTS
Producer Yapı Merkezi Prefabrication
Ring Diameter * Outer (13.2 m)* Inner (12.0 m)
Segment Length 2 m
Segment Thickness 0.6 m
Ring Arrangement * Universal* 8 + 1 keystone
Segment Weight ~ 15 t
Ring Weight ~ 127 t
ERQ 28-days Comp. Strength Limit 50 MPa
Average 28-days Comp. Strength of Production 72 MPa
ERQ Rapid ChloridePermeability Limit 1000 Coulomb
Average Rapid ChloridePermeability 280 Coulomb
ERQ Service Life Limit 100 years
Estimated Minimum Service Life 127 years
15.048 piece 600-mm-thick precast segments (1.672 rings)
27.100 t cement
200 t hyperplasticizer
4.800 t fly ash
66 ton polypropylene fiber
79.468 m³ concrete
More than 60.000 QA/QC tests Connected by using 30.765 bolts
Only 0.3% of producedsegmenst were found tobe deficient due toexistance of cracks withwidth more than 0.2 mm.
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COMPARISON OF TBM TUNNEL PROJECTS (FACE PRESSURES AND DIAMETERS)
0 500 1000 1500 2000 2500
TTBM Design
Applied
Lake Mead, USA
Eurasia, TURKEY
Hallandsas, SWEDEN
Shanghai Chongming, CHINA
Nanjing, CHINA
Weser, GERMANY
St Petersburg, RUSSIA
Tokyo Wan, JAPAN
Hamburg – Elbe, GERMANY
Westerschelde, NEDERLAND
=7.2 m
=13.7 m=10.6 m
=15.4 m
=14.9 m
=11.7 m
=7.4 m
=14.1 m
=14.2 m
=11.3 m
DIAMETER2 X PRESSURE (m2.bar)
Eurasia Tunnel TBM ( = 13.7 m) is leading the investigated group of 10 projects when the
“Diameter2 x Pressure” parameter is considered. Source: Untreated data from Anagnostou(2014) and Holzhauser et al. (2006)
HIGHEST DESIGN PRESSURE Pf-design = 17.0 bar
Pf-design = 12.0 bar
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ADVANCE RATES BASED ON VARIOUS UNITS
As expected, the coefficient of variation value i.e. magnitude of variability in advance ratewas obtained highest in daily advance rate.
The ratio of (maximum value / average value) was varying between 1.5 and 2.6.
Statistical Parameters Daily Weekly Monthly
Time 476 days 68 weeks 16 months
Maximum 18.0 m/day 86.7 m/week 316.0 m/month
Minimum 0 0 90.0 m/month
Average 7.0 m/day 49.0 m/week 208.3 m/month
Standard Deviation 5.1 m/day 26.6 m/day 64.4 m/day
Coefficient of variation 72 % 54 % 31 %
Source: Yapı Merkezi R&D Department, 2015©
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DAILY ADVANCE RATE & SHIELD DIAMETERD
aily
Adv
ance
Rat
e, m
/day
Tunnel Diameter, D, m0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0
2
4
6
8
10
12
14
16
18
20
22
24
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Lower Lİmit
Upper Limit
Project Name General Geology/ Formation
Grauholz (1) Sand, Gravel, Debris
Mülheim (1) Sandstone, Claystone
Strasbourg (1) Gravel, Sand
Taipei (1) Clay
Cairo (1) Sand
Duisburg (1) Limestone, Gravel, Clay
Heinenoord (1) Sand, Clay
Zurich Glatt (1) Debris,unconsolidated materials
Sydney (1) Clay, sand, sandstone
Buenos Aires (1) Sand, Gravel, Clay
Hamburg (1) Gravel, marn, rock block
Berlin (1) Sand, clay
İzmir (1) Sand, clay
Madrid (1) Clayey Soil, sand, clay
Düsseldorf (1) Fine sand, sandy gravel, stones
Singapore (1) Sediment, clay
Botlek (1) Clay, coarse sand, gravel
SMART(2) Carstic limestone, sediment
Lefortovo(3) Sand carrying water, silt, laminated limestone alternatedkil
Channel Tüneli(4)
Limestone, marn, weak sandstone
(1) Values were taken from TKJV TBM Expert Report, 2009.(2) Carter & Burgess, Inc., 2007.(3) Herrenknecht, Bäppler, 2006.(4) Harris, vd., 1996.
Upper U ppep rppUpperLimitL mitiLimit
D=1
3.7m
Formation / Section Ave.
Trakya Formation (4 days of Holiday excluded)
6.8 m/day
Transition Zones 8.6 m/day
Marine Sediments (4 daysHoliday & 13 days seismic joints)
9.2 m/day
Overall 7.0 m/day
Overall without MandatoryStandstills (8 days Holiday & 13 days seismic joints)
7.3 m/day
Overall without MajorStandstills (112 days of majorstandstills that are more 1 day)
9.1 m/day
r r LimitL miti t
tion Avee. .
days of 6.8m/day
8.6 m/day
daysic joints)s
9.2m/day
7.0 m/day
Source: Yapı Merkezi R&D Department, 2014©
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COMPARISON OF EURASIA / SHANGAI-I / SHANGAI-II MIXSHIELD TBM PROJECTS
Project Name EURASIA SHANGAI - I SHANGAI - II
Project Country Turkey China China
GeologyTrakya & Marine
SedimentsSand & Clay Sand and Clay
TBM Tunnel Length (m) 3340 7476 7472
TBM Tunnel Type Highway Highway Highway
TBM Manufacturer Herrenknecht Herrenknecht Herrenknecht
TBM Type Mix-Shield Mix-Shield Mix-Shield
TBM Diameter (m) 13.7 15.4 15.4
TBM Cutterhead Power (kW) 4900 3750 3750
Cutterhead Power per Unit Area (kW/m2)
33.3 20.2 20.2
Wee
kly
Adv
ance
Rat
e Number of Weeks 68 88 73
Maximum (m) 86.7 (@ marine sediments) 144 140
Minimum (m) 0 0 0
Average (m) 49.0 85.0 88.8
Standard Deviation (m) 26.6 36.3 35.3
Coefficient of Variation (%) 54 43 40
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At first glance, weekly advance rate in Shangai-I and Shangai-II TBM Projects are markedly
higher than Eurasia Tunnel.
Taking consideration into magnitude of "face support pressure x cross section area of
cutterhead", one obtains the following figures:
Eurasia Tunnel….…………..120 t/m2 x (π/4) x (13.7 m)2 = 17680 t
Shangai Tunnel…………….. 60 t/m2 x (π/4) x (15.4 m)2 = 11170 t
The horizontal force resulting from face support pressure at Eurasia Tunnel is about 1.58
times higher than Shangai Tunnels.
There is no section with highly fractured rock mass in route of Shangai tunnels. Hence, it is
expected to experience higher penetration rate leading to ultimately higher weekly advance
rate. As for the borability of TBM in Eurasia Tunnel Project, ground is extremely variable
from one point to other point due to different stiffness and jointing degree.
COMPARISON OF EURASIA / SHANGAI-I / SHANGAI-II MIXSHIELD TBM PROJECTS
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FACE SUPPORT PRESSURE & TOTAL THRUST FORCE
Excavationn Direction
239000 kN(97 % of design capacity)
10.8 bar(90 % of design capacity)
1st Hyperbaric Maintenancefor "Suction Grid Repair"
at ction Grid Reat 10.8 bar
2nd Hyperbaric Maintenancefor "Cutterhead Inspection"
at erhead Inspeat 10.3 bar
3rd Hyperbaric Maintenancefor "Suction Grid Repair"
at tion Grid Reat 9.8 bar
4th Hyperbaric Maintenancefor "Boulder Crusher Repair"
at er Crusher
at 8.5 bar
Abo
vee4.
5 ba
r,
r,sa
tura
tionn
divi
nggis
ssre
quir
edA
bov
for
vee.5
bar
4r,
sabo
voroor
man
inte
nanc
eatur
a cececece/
atio
nra
tur
eee///re
pair
ivin
gd
gis
seqre
onnd
irirrop
erat
ions
Source: Arioglu et al. 2016©
31
DETAILED OVERVIEW OF STANDSTILLS
No Ring(distance)
CompletedTunnel (%)
Face SupportPressure (bar)
Duration(days) Description of Standstill
1 126(252 m)
7.5 4.2 20Cutterhead repair by compressed air diving (Cutterhead damaged due to failure of disc cutter sensors thereby failure of gauge cutters. Some buckets replaced, composite plates and pins welded)
2 195(390 m)
11.7 5.2 9 Disc cutter replacement under athmospheric pressure
3 270(540 m)
16.2 6.0 9 Disc cutter replacement under athmospheric pressure
4 430(860 m)
25.7 8.2 6 Asian side seismic joint installation
5 568(1136 m)
34.0 9.0 4 Religious holiday
6 587(1174 m)
35.1 9.7 6Cutting tool and brush replacement under athmosphericpressure
7 690(1380 m)
41.3 10.1 7 European side seismic joint installation
8 875(1750 m)
52.4 10.8 15 Suction grid repair by saturation diving
9 933(1866 m)
55.9 10.5 8 Cutterhead inspection by saturation diving (6 cm x 75 cm x 200 cm metal pieces were taken out from jaw crusher area)
10 1003(2006 m)
60.1 10.1 5 Suction grid repair by saturation diving (Middle section of the old suction grid was removed and the new one was installed)
11 1146(2292 m)
68.6 8.9 19 Boulder crusher repair by saturation diving
12 1499(2998 m)
89.8 4.2 4 Religious holiday
Total Standstills 112 Note that 8 days holiday and 13 days seismic joint installations weremandatory.
Source: Yapı Merkezi R&D Department, 2016©
32
SUMMARY OF HYPERBARIC WORKS UNDER APPROXIMATELY 11 BAR PRESSURE
Starting from excavation of Ring-870 (1740 m), someblockage issues in suction line was observed and inconsecutive 5 days daily advance rate is approximately1.7 m/day due to same issue (5 days period averagecutterhead speed, penetration, total thrust force and torquevalues are 1.8 rpm, 6.7 mm/revolution, 162 MN and 6.2 MNm,respectively). Operational parameters indicate anomally.
Blocked pipes were investigated and larger diameterrock units were identified. It was thought that reason isthe damaged / deteriorated grid behind the stone crusher.The grid became non-functional. For this reason,hyperbaric works were carried out at Ring-875 (1750 m).
The summary of condition at Ring-875 is as follows:
Excavated Geological Unit: Trakya Formation (RockQuality Designation, RQD < 25 % and very weak highly jointedrock mass conditions)
Face Pressure: 10.8 bar (90 % of the TBM design pressure)
Depth of TBM Tunnel -bottom of tunnel from sealevel-: ~103.0 m (note that the deepest point was 106.4 m)
Type of Hyperbaric Works: Saturation
Total Standstill Duration of TBM for HyperbaricMaintenance: 14 days
Stuckedd SSStones Stuckedd Stone (~24 cm)
New w Grid
Technical Drawing of
Grid
Damagedd Grid
DiversDiversSource: Yapı Merkezi R&D Department, 2015©
33
CUTTERHEAD TORQUE
Average cutterhead torque values in Asia side Trakya formation, marine sediments and Europe sideTrakya formation are 10.0 MNm, 4.5 MNm and 6.0 MNm, respectively.
Torque values were representing a high variation (38 %) in Asia side Trakya formation due to varyingformation characteristics. When the marine sediment excavation started, torque values were decreasedand the variations were decreased to (22 %).
Euro
pean
Side
Sei
smic
Join
t
Asi
anSi
de S
eism
icJo
int
Europe – Trakya FormationMarine Sediments and Transition ZonesAsia – Trakya Formation
Source: Yapı Merkezi R&D Department, 2015©
34
CUTTERHEAD TORQUE AND SPEED
Prod
ucer
Lim
it =
3.2
rpm
Limit Torque
Nominal Torque
Cut
terh
ead
Torq
ue(M
Nm
)
Cutterhead Speed (revolution per minute)Source: Yapı Merkezi R&D Department, 2015©
Trakya Formation
Marine Sediments
35
SPECIFIC ENERGY CONSUMPTION
The lowest cutterhead electricity consumption was observed during excavation of marine sediments withan average specific energy value of 3.1 kWh/m3. Spent average specific energy in Asia and Europe sideTrakya formation were 15.9 kWh/m3 and 14.3 kWh/m3, respectively.
At some rings, it was observed that the specific energies were jumped due to existance of dyke zones.
Euro
pean
Side
Sei
smic
Join
t
Asi
anSi
de S
eism
icJo
int
Europe – Trakya FormationMarine Sediments and Transition ZonesAsia – Trakya Formation
Source: Yapı Merkezi R&D Department, 2015©
36
RELATIONSHIP BETWEEN SPECIFIC ENERGY AND PENETRATION
Curve approximated by Authors based on thedata given in Barla (2000).( 11.8m; through Dolomite, Limestone and Argillite Formations)
Curve generated from the Eurasia Tunnel data
37
RINGBUILD DURATION
Source: Limits by Maidl and Comulada (2011), Eurasia
data by Yapı Merkezi R&D Department, 2015©
EurasiaTunnel(φ13.7 m)
Learning Period
Eurasia Tunnel TBMMaximum segment weight is 15 t andcomplete weight of 8+1 ring is 127 t.Segment erector's rated load is 16 t.
38
TBM EXCAVATION PARAMETERS
Excavation ParametersAsia
Trakya Formation(Rings: 0 - 282)
AsiaTransition Zone(Rings: 283 - 338)
Marine Sediments
(Rings: 339 - 714)
EuropeTransition Zone(Rings: 715 - 770)
EuropeTrakya Formation(Rings: 771 - 1670)
Overall(Rings: 0 - 1670)
Excavation Dates 5/5/14 - 6/8/14 7/8/14 - 15/8/14 16/8/14 - 22/11/14 23/11/14 - 9/12/14 10/12/14-23/8/15 5/5/14-23/8/14
Calendar Days 94 9 99 17 257 476
Major Stop Days 38 0 23 0 51 112
Section Length (m) 564 112 752 112 1800 3340
Average Advance Speed (mm/minute) 20.2 28.6 24.4 14.9 13.9 17.8
Average Penetration (mm/revolution) 9.2 10.0 18.4 7.0 5.9 9.4
Average Cutterhead Speed (rev. per minute) 2.2 2.9 1.5 2.2 2.4 2.2
Average Torque (MNm) 9.8 7.6 3.7 7.0 6.0 6.2
Minimum Total Thrust Force (kN) 57,841 94,406 106,920 154,476 21,679 21,679
Maximum Total Thrust Force (kN) 113,240 122,683 238,935 210,517 199,412 238,935
Min. Pressure -TOP- (bar) 0 5,3 6,2 9,4 0 0
Max. Pressure -TOP- (bar) 5.4 6.3 9.6 9.7 9.8 9.8
Specific Energy (kWh/m3) 15.9 10.6 3.4 17.1 14.3 12.1
Average Advance (minutes/ring) (*) 105 71 84 145 146 123
Average Ringbuild (minutes/ring) (**) 62 45 53 51 44 49
Average Downtime (minutes/ring) (***) 105 100 97 129 101 102
(*) Higher advance durations (tadvance > 300 minutes/ring) are excluded.(**) Higher ringbuild durations (tringbuild > 120 minutes/ring) are excluded.(***) Major stop durations (tdowntime > 1,000 minutes/ring) are excluded. Source: Yapı Merkezi R&D Department, 2015©
39
REPLACED DISC CUTTERS, SCRAPERS AND BRUSHES
ToolAsia Side
Trakya Formation(0 – 564 m)
Transition Zones andMarine Sediments
(565 m - 1540)
Europe SideTrakya Formation(1541 m – 3340 m)
TotalNumber
Disc Cutter 54 69 325 448
Scraper 16 17 52 85
Brush 0 475 0 475
DiscCutterType
Number on Cutterhead
Average ExcavatedLinear TunnelDistance (m)
Average TrackedLength (km)
AverageExcavated
Volume (m3)
Center 6 1534 834 1445
Face 23 284 984 1126
Gauge 6 97 697 703
Replacement number of tools by considering formation in Eurasia Tunnel.
Some excavation parameters by considering disc cutter type in Eurasia Tunnel.
Source: Yapı Merkezi R&D Department, 2015©
Source: Yapı Merkezi R&D Department, 2015©
40
Geometric Restrictions:
Tunnel diameter (two-deck road tunnel)
Overburden (minimum 2 times diameter)
Gradients (±5%)
Highly Active Seismicity:
Slip rate of about 20-24 mm/year on fault system based on the GPS measurements
Distance to North Anatolian Fault Zone is 16 km
The probability of a Mw ≥ 7.0 earthquake is 35 – 70 % in the next 30 years
First application of seismic joint for subsea tunnel in worldwide
Extremely Variable Geology:
Subjected to twice "orogenic events" in history
Trakya formation with volcanic dyke intrusions (5 – 250 MPa)
Transition zones
Faulted and weakness zones
Marine sediments
MAJOR CHALLENGES - I
41
Hyperbaric and Operational Conditions:Risky project since face support pressures were above 4.5 bar for 79% of the alignment with respect ofsaturation diving by nitrox/trimix gas mixture
Saturation diving with nitrox/trimix gas mixture where face support pressures are above 4.5 bar
First application of hyperbaric operation under 11 bar in worldwide TBM projects.
4 times hyperbaric maintenance/repairs
Aggressive Medium:
Volcanic dykes of andesite and diabase.
28 dyke intrusions
Total length of 413 m (12 % of tunnel)
Frequency of about 90 m
Thicknesses between 1 m and 120 m
UCS more than 200 MPa
CAI values are reaching up to 4.5 (“abrasive” and “very abrasive” classes)
High Capacity Demands:
Face support pressure of 10.8 bar (90% of capacity)
Thrust force of 239 MN (97% of installed capacity)
Torque of 20 MNm (86% of nominal capacity)
Separation plant usage for 18.0 m/day (90% of capacity which is 2800 m3/day)
MAJOR CHALLENGES - II
42
CONCLUSION
Responses to ChallengesPreliminary studies (literature/desk studies and detailed site/laboratory investigations)
Latest Mixshield TBM technology (advanced monitoring systems, atmospherically changeable cutting tools, special pressure equipment)
Seismic Joints (innovated, designed, localized, tested, implemented)
Continuous monitoring and utilization of gained knowledge (excavation parameters and downtime root causes) on upcoming excavation phases
Best experts for all aspects of the project
Utilizing and developing technologyEffective learning (cutting tool replacement duration, ringbuild duration, interaction between rockmass/soil andTBM, practical solutions at site)
Experienced TBM crew (average 2.8 TBM projects / personnel and average 15.0 km TBM tunnel / personnel)
Collaborative and succesful Project Management and Yapı Merkezi Prefabrication Factory
Breakthrough: 22/08/2016 - 17:00
Average Daily Advance Rate: 7.0 m/day
Utilization Ratio: 31%
43
Owner : Ministry of Transportation
General Directorate of Infrastructure Investments (AYGM)
Investor/Contractor : Avrasya Tüneli İşletme, İnşaat ve Yatırım A.Ş. (ATAŞ)
Yapı Merkezi and SK EC Joint Venture (YMSKJV)
Yapı Merkezi : Board Members
Host : Turkish Tunnelling Society
ACKNOWLEDGEMENT
“... the Project will encourage the tunnelingworld to attempt deeper, farther and larger ...”
Dr. Ersin ARIOĞLU (2015)Founder of Yapı Merkezi
44
Wee wouldd likee too thankk youWee wfor
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ankhathttt in
youyankknn ourr youry r nteresin t
presentationn ot ninn
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Source: Arıoğlu, Ersin (2016)