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B. Maidl, M. Herrenknecht, U. Maidl, G. Wehrmeyer
Mechanised Shield Tunnelling
2nd Edition

Mechanised Shield Tunnelling

Bernhard Maidl
Martin Herrenknecht
Ulrich Maidl
Gerhard Wehrmeyer
Prof. Dr.-Ing. Bernhard Maidl Dr.-Ing. E.h. Martin Herrenknecht
mtc – Maidl Tunnelconsultants GmbH & Co. KG Herrenknecht AG
Fuldastr. 11 Schlehenweg 2
47051 Duisburg 77963 Schwanau

Dr.-Ing. Ulrich Maidl Dr.-Ing. Gerhard Wehrmeyer

mtc – Maidl Tunnelconsultants GmbH & Co. KG Herrenknecht AG
Fuldastr. 11 Schlehenweg 2
47051 Duisburg 77963 Schwanau

Translated by David Sturge, Kirchbach, Germany

Cover: Herrenknecht-EPB-Shield S-300 Madrid M-30

By-Pass Sue Túnel Norte, Madrid, Spain
Photo: Herrenknecht AG

Library of Congress Card No.:

applied for

British Library Cataloguing-in-Publication Data

A catalogue record for this book is available from the British Library.

Bibliographic information published by

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

© 2012 Wilhelm Ernst & Sohn, Verlag für Architektur und technische Wissenschaften GmbH & Co. KG, Rotherstr. 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.

Coverdesign: Sonja Frank, Berlin, Germany

Produktion management: pp030 – Produktionsbüro Heike Praetor, Berlin
Typesetting: Reemers Publishing Services GmbH, Krefeld
Printing and Binding: Strauss GmbH, Mörlenbach

Printed in the Federal Republic of Germany.

Printed on acid-free paper.

2nd Edition
Print ISBN: 978-3-433-02995-4
ePDF ISBN: 978-3-433-60150-1
ePub ISBN: 978-3-433-60149-5
mobi ISBN: 978-3-433-60148-8
o-Book ISBN: 978-3-433-60105-1
„A plan whatever it may be
must be made for the bad ground,
it must be calculated to meet all exigencies, all disasters
and to overcome them after they have occured.“
Marc Isambard Brunel
on suggested improvements
after the flooding of the Thames Tunnel in 1831.
The authors

1 Introduction B. Maidl
2 Support of the cavity and settlement U. Maidl
3 Construction and design methods G. Wehrmeyer
4 Excavation tool and excavation process M. Herrenknecht
G. Wehrmeyer
5 Muck removal M. Herrenknecht
G. Wehrmeyer
6 The tunnel lining B. Maidl
7 Shield tail sealing, grouting works G. Wehrmeyer
8 Open shields B. Maidl
9 Compressed air shields B. Maidl
10 Slurry shields U. Maidl
11 Earth pressure shields U. Maidl
12 Convertible shields B. Maidl
13 Special shields and special processes B. Maidl
14 Guided microtunnelling processes B. Maidl
15 Surveying and steering M. Herrenknecht
G. Wehrmeyer
16 Workplace safety B. Maidl
17 Partnering contract models and construction U. Maidl
18 Process controlling and management U. Maidl

19 DAUB recommendations for the selection of tunnelling machines U. Maidl

Mechanised Shield Tunnelling, 2nd Edition

B. Maidl, M. Herrenknecht, U. Maidl, G. Wehrmeyer
Copyright © 2011 Ernst & Sohn, Berlin
Foreword to the 2nd Edition

The rapid progress of mechanised tunnelling to market leadership has continued – even
exceeded predictions; the general worldwide trend in construction towards mechanisation
and automation clearly demanded a similar development in tunnelling. It is significant that
even in Austria, the traditional home of the New Austrian Tunnelling Method (NATM),
mechanised tunnelling has also established its position in the last decade. Occupational
health and safety, faster advance rates, improved cost security and labour-saving opened
opportunities for mechanised tunnelling on a few major projects – normally in competi-
tion with conventional construction methods.
So it is appropriate that this book should now be revised, 20 years after its first publica-
tion. The extent of innovations and practical experience led to a complete reworking. Inci-
dentally, the book “Hardock Tunnel Boring Machines“, which appeared in 2008, already
offered access to the newest technology in the area of tunnel support. The team of authors
has adapted the content to the latest technology and has been supplemented to provide the
necessary specialist knowledge.
The original authors B. Maidl and M. Herrenknecht also worked on this edition. We have
gained my son Dr.-Ing. U. Maidl and my former doctoral candidate Dr.-Ing. G. ­Wehrmeyer,
who have particularly devoted themselves to new developments.
I am very thankful that I could still rely on the help of my former employees Herr H.
Schmidt and Herr G. Kaufhold for the new revision. I would like to thank Herr Dipl-Ing.
M. Griese from MTC, who helped a great deal with the detailed work and overall coordi-
nation. I would also like to thank my grandson Max Maidl for his assistance. A thank-you
to all, especially the author colleagues and the publisher.

Bochum, January 2011 Bernhard Maidl

Mechanised Shield Tunnelling, 2nd Edition

B. Maidl, M. Herrenknecht, U. Maidl, G. Wehrmeyer
Copyright © 2011 Ernst & Sohn, Berlin
Table of Contents

The authors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

Foreword to the 2nd Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Basic principles and terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Types of tunnel boring machine according to DAUB . . . . . . . . . . . . . . . . . . . 5
1.2.1 Categories of tunnelling machines German association for
underground construction (TVM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Tunnel boring machines (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.2.1 Tunnel boring machines without shield (gripper TBM) . . . . . . . . . . 6
1.2.2.2 Reamer tunnel boring machines (ETBM) . . . . . . . . . . . . . . . . . . . . 7
1.2.2.3 Tunnel boring machines with single shield (TBM-S) . . . . . . . . . . . 7
1.2.3 Double shield machines (DSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4 Shield machines (SM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.4.1 Shield machines with full-face excavation (SM-V) . . . . . . . . . . . . . 8
1.2.4.2 Shield machines with partial face excavation (SM-T) . . . . . . . . . . . 11
1.2.5 Adaptable shield machines with combined process technology
(KSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.6 Special types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.6.1 Blade shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.6.2 Shields with multiple circular cross-sections . . . . . . . . . . . . . . . . . . 12
1.2.6.3 Articulated shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.7 Remarks about the individual types of tunnelling machines
with diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.7.1 Tunnel boring machines (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.7.2 Double shield machines (DSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.7.3 Face without support (SM-V1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.7.4 Face with mechanical support (SM-V2) . . . . . . . . . . . . . . . . . . . . . . 14
1.2.7.5 Face with compressed air (SM-V3) . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.7.6 Face with slurry support (SM-V4) . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.7.7 Face with earth pressure support (SM-V5) . . . . . . . . . . . . . . . . . . . . 14
1.2.7.8 Face without support (SM-T1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.7.9 Face with partial support (SM-T2) . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.7.10 Face with compressed air support (SM-T3) . . . . . . . . . . . . . . . . . . . 15
1.2.7.11 Face with slurry support (SM-T4) . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.7.12 Adaptable machines (KSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Origins and historical developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2 Support of the cavity and settlement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.1 Support of the face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1.1 Natural support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1.2 Mechanical support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Mechanised Shield Tunnelling, 2nd Edition

B. Maidl, M. Herrenknecht, U. Maidl, G. Wehrmeyer
Copyright © 2011 Ernst & Sohn, Berlin
XII Table of Contents

2.1.3 Compressed air support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.1.4 Slurry support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1.5 Earth support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.1.6 Calculation models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Support of the cavity at the shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3 Support of the cavity behind the shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Settlement and damage classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4.1 Empirical determination of the settlement . . . . . . . . . . . . . . . . . . . . 41
2.4.2 Numerical models for the calculation of settlement . . . . . . . . . . . . . 43
2.5 Heave and compaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3 Design and calculation methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.1 Constructional parts of the shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Loading on the shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2.1 Loading on the shield skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2.2 Loading on the pressure bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2.3 Loading from the thrust cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3 Calculation of the necessary thrust force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.3.1 Resistance to advance through friction on the shield skin . . . . . . . . 55
3.3.2 Resistance to advance at the front shield . . . . . . . . . . . . . . . . . . . . . 56
3.3.3 Resistance to advance at the face through platforms and
excavation tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.4 Resistance to advance with slurry support, earth support and
compressed air support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.3.5 Resistance to advance from steering the shield . . . . . . . . . . . . . . . . 58
3.3.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.4 Empirical values for the dimensioning of the shield
and the thrust cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.5 Calculation and dimensioning basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.6 Regulations and recommendations for the design of shields . . . . . . . . . . . . . . 62

4 Excavation tools and excavation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4.1 Excavation tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1.1 Hand-held tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1.2 Cutting edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.1.3 Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.1.4 Drag picks, flat chisels, round chisels, rippers . . . . . . . . . . . . . . . . . 66
4.1.5 Disc cutters, discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1.6 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Excavation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2.1 Tunnelling without cutting wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.2 Manual digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.3 Partial-face mechanical excavation . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.4 Mechanical full-face excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.5 Hydraulic excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2.6 Alternative excavation processes . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
 Table of Contents XIII

5 Muck removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.1 Preparation for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.2 Removal from the face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.2.1 Open shield machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2.2 Shield machines with pressure chamber . . . . . . . . . . . . . . . . . . . . . . 95
5.3 Transport along the tunnel and up shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.3.1 Open transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.3.2 Piped transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.4 Quantity determination and measuring equipment . . . . . . . . . . . . . . . . . . . . . . 105
5.5 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.5.1 Separating process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.5.2 Separating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.6 Suitability of the muck for landfill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

6 The tunnel lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.2 Construction principles for the tunnel lining . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.2.1 Single-layer and Double-layer construction . . . . . . . . . . . . . . . . . . . 118
6.2.2 Watertight and water draining construction . . . . . . . . . . . . . . . . . . . 119
6.3 Segmental lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.3.2 Constructional variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.3.2.1 Block segments with rectangular plan . . . . . . . . . . . . . . . . . . . . . . . 122
6.3.2.2 Hexagonal segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.3.2.3 Rhomboidal and trapezoidal segment systems . . . . . . . . . . . . . . . . . 126
6.3.2.4 Expanding segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.3.2.5 Yielding lining systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.3.3 Joint details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.3.3.1 Longitudinal joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.3.3.2 Ring joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.3.4 Steel fibre concrete segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3.5 Filling of the annular gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3.5.1 Filling with gravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3.5.2 Mortar grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3.6 Measures to waterproof tunnels with segment linings . . . . . . . . . . . 141
6.3.6.1 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.3.6.2 Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.3.7 Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.3.8 Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.3.8.1 Damage during ring building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.3.8.2 Damage while advancing the machine . . . . . . . . . . . . . . . . . . . . . . . 145
6.3.8.3 Damage in the shield tail seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.3.8.4 Damage after leaving the shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.3.8.5 Repair of damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
XIV Table of Contents

6.4 In-situ concrete lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

6.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.4.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.4.3 Concreting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.5 Injected concrete, Extruded concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.6 Shotcrete layers as the final lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6.7 Structural calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7 Shield tail sealing, grouting works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

7.1 Shield tail seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.1.1 Plastic seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.1.2 Steel brush seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.1.3 Outer shield tail seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.1.4 Elastically supported face formwork for the extrusion process . . . . 161
7.2 Grouting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.2.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.2.2 Conception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.2.3 Grouting systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.2.4 Grout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.3 Grouting for ground improvement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.3.1 Machinery and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.3.2 Grout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
7.3.3 Grouting work at the Channel Tunnel . . . . . . . . . . . . . . . . . . . . . . . 173

8 Open shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

8.1 Shield construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.1.1 Hand shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.1.2 Part-face excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
8.1.3 Full-face excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.2 Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.2.1 Example: Eurotunnel – under the English Channel, 1988 to 1991 . 181
8.2.2 Arrowhead Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
8.3 Double shields [203] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.3.1 Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.3.2 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.3.3 Special features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
8.3.3.1 Shield skin and bentonite lubrication . . . . . . . . . . . . . . . . . . . . . . . . 196
8.3.3.2 Telescopic shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
8.3.3.3 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

9 Compressed air shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

9.1 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
9.2 Compressed air facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.2.1 Air locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9.2.2 Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9.2.3 Compressed air regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
 Table of Contents XV

9.3 Air requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

9.3.1 Determination of air requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9.3.2 Verification of safety (blowout safety) . . . . . . . . . . . . . . . . . . . . . . . 212
9.3.3 Special processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9.4 Further developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.4.1 Compressed air shield with unpressurised working space and
full-face excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.4.2 Compressed air shield with unpressurised working spaces and
part face excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.4.3 Membrane shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
9.5 The use of compressed air with other types of shield . . . . . . . . . . . . . . . . . . . . 216
9.6 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.6.1 Old Elbe Tunnel next to the St. Pauli landing stage, 1907 to 1911 . 217
9.6.2 Energy supply tunnel under the Kiel Fjord, 1989/90 . . . . . . . . . . . . 219

10 Slurry shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

10.1 Development history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
10.2 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
10.3 Scope of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
10.4 Machine types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
10.4.1 Full-face machines with fluid support . . . . . . . . . . . . . . . . . . . . . . . 228
10.4.2 Part face machines with slurry support . . . . . . . . . . . . . . . . . . . . . . . 233
10.5 Machine and process technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
10.5.1 Soil excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
10.5.2 Muck transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
10.6 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.6.1 Westerschelde . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
10.6.2 Lower Inn Valley railway, Münster/Wiesing Tunnel, main contract
H3-4; Jenbach/Wiesing Tunnel, main contract H8, 2007 to 2009 . . . . 243
10.6.3 Fourth bore of the Elbe Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
10.6.4 Chongming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

11 Earth pressure balance shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

11.1 Development history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
11.2 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
11.2.1 Support pressure measurement and control . . . . . . . . . . . . . . . . . . . 256
11.2.2 Soil conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
11.2.3 Mass-volume control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
11.3 Areas of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
11.4 Operating modes and muck transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
11.4.1 Open mode (screw conveyor – conveyor belt) . . . . . . . . . . . . . . . . . 264
11.4.2 Semi open mode (screw conveyor – conveyor belt) . . . . . . . . . . . . . 265
11.4.3 Closed mode (hydraulic mucking circuit) . . . . . . . . . . . . . . . . . . . . 266
11.4.4 EPB mode (screw conveyor – conveyor belt or
screw conveyor – piston pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
11.4.5 Open mode (conveyor belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
XVI Table of Contents

11.5 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

11.5.1 Cutting wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
11.5.2 Bearing and drive construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
11.5.3 Excavation chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.5.4 Screw conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
11.5.5 Foam conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
11.6 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
11.6.1 Katzenberg Tunnel on the new railway line Karlsruhe – Basel,
2005 to 2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
11.6.2 Madrid M-30 (Bypass Sur Tunnel Nord) . . . . . . . . . . . . . . . . . . . . . 280
11.6.3 Heathrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
11.6.4 DTSS Singapore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

12 Convertible shields or multi mode machines . . . . . . . . . . . . . . . . . . . . . . . . . 291

12.1 Development strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
12.1.1 Convertible shield with integrated components for
multiple operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
12.1.2 Building block systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
12.2 Machine concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
12.2.1 Mixshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
12.2.2 Polyshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
12.3 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
12.3.1 Grauholz Tunnel, 1990 to 1993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
12.3.2 Zürich Thalwil contract 2.01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
12.3.3 Socatop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

13 Special shields and special processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

13.1 Blade shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
13.1.1 Face support with blade shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
13.1.2 Support types with blade shields . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
13.2 Multi-face shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
13.2.1 Arrangement of the cutting wheels in multi-face shields . . . . . . . . . 316
13.2.2 Tunnel support with multi-face shields . . . . . . . . . . . . . . . . . . . . . . 317
13.3 Enlargement of shield tunnels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
13.4 Pipe jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
13.4.1 Pipe jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
13.4.2 Box jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
13.5 New concepts in mechanised shield tunnelling . . . . . . . . . . . . . . . . . . . . . . . . . 328
13.5.1 Shield machines for flexible cross-sections . . . . . . . . . . . . . . . . . . . 328
13.5.2 Ultra-flexible shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
13.5.3 Horizontal and vertical shield machines . . . . . . . . . . . . . . . . . . . . . . 330
13.5.4 Enlargement shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
13.5.5 Rotation shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
13.5.6 Shield docking method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
 Table of Contents XVII

14 Guided microtunnelling processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

14.1 Pilot tube process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
14.2 Auger microtunnelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
14.3 Shield microtunnelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
14.4 English Mini Tunnel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
14.5 New developments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

15 Surveying and steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

15.1 Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
15.1.1 Navigation with tunnel laser and automatic target unit . . . . . . . . . . 351
15.1.2 Navigation with gyroscope system and hose water level . . . . . . . . . 351
15.1.3 Navigation with total station and automatic target unit . . . . . . . . . . 352
15.1.4 Navigation with total station and prisms . . . . . . . . . . . . . . . . . . . . . 353
15.2 Ring design and calculation of the ring installation sequence . . . . . . . . . . . . . . 354
15.3 Ring convergence measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
15.4 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
15.5 Further surveying and data logging tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

16 Workplace safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

16.1 General safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
16.2 Control stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
16.3 Electrical cut-out and safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
16.4 Control devices and control systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
16.5 Towing connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
16.6 Laser guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
16.7 Ventilation and the control of dust and gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
16.8 Fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
16.9 Storage of safety equipment for the personnel . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.11 Content of handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
16.12 Evaluation of risk in mechanised tunnelling [26] . . . . . . . . . . . . . . . . . . . . . . . 370

17 Partnering contract models and construction . . . . . . . . . . . . . . . . . . . . . . . . . 383

17.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
17.2 Requirements for the contract model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
17.3 Contract model according to VOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
17.4 Time and cost drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
17.5 Under-pricing as a performance killer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
17.6 Chances and risks of partnering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
17.7 Partnering – contractual implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
17.8 Partnering – mutual process optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

18 Process controlling and data management . . . . . . . . . . . . . . . . . . . . . . . . . . 393

18.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
18.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
18.3 Data management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
XVIII Table of Contents

18.4 Target-actual comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

18.5 Target process structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
18.6 Analysis of the actual process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

19 DAUB recommendations for the selection of tunnelling machines . . . . . . . . 401

19.1 Preliminary notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
19.2 Regulatory works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
19.2.1 National regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
19.2.2 International standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
19.2.3 Standards and other regulatory works . . . . . . . . . . . . . . . . . . . . . . . 403
19.3 Definitions and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
19.3.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
19.3.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
19.4 Application and structure of the recommendations . . . . . . . . . . . . . . . . . . . . . . 406
19.5 Categorisation of tunnelling machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
19.5.1 Types of tunnelling machine (TVM) . . . . . . . . . . . . . . . . . . . . . . . . 408
19.5.2 Tunnel boring machines (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
19.5.2.1 Tunnel boring machines without shield (Gripper TBM) . . . . . . . . . 408
19.5.2.2 Enlargement tunnel boring machines (ETBM) . . . . . . . . . . . . . . . . . 409
19.5.2.3 Tunnel boring machine with shield (TBM-S) . . . . . . . . . . . . . . . . . 410
19.5.3 Double shield machines (DSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
19.5.4 Shield machines (SM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
19.5.4.1 Shield machines for full-face excavation (SM-V) . . . . . . . . . . . . . . 410
19.5.4.2 Shield machines with partial face excavation (SM-T) . . . . . . . . . . . 413
19.5.5 Adaptable shield machines with convertible process technology
(KSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
19.5.6 Special types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
19.5.6.1 Blade shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
19.5.6.2 Shields with multiple circular cross-sections . . . . . . . . . . . . . . . . . . 414
19.5.6.3 Articulated shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
19.5.7 Support and lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
19.5.7.1 Tunnel boring machines (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
19.5.7.2 Tunnel boring machines with shield (TBM-S), Shield machines
(SM, DSM, KSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
19.5.7.3 Advance support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
19.5.7.4 Support next to the tunnelling machine . . . . . . . . . . . . . . . . . . . . . . 418
19.6 Ground and system behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
19.6.1 Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
19.6.2 Ground stability and face support . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
19.6.3 Excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
19.6.3.1 Sticking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
19.6.3.2 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
19.6.3.3 Soil conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
19.6.3.4 Soil separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
19.6.3.5 Soil transport and tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
19.7 Environmental aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
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