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A tunnel boring machine (TBM), also known as a "mole" or a "worm", is a machine used to excavate tunnels. Tunnels are excavated through hard rock, wet or dry soil, or sand, each of which requires specialized technology.
Tunnel boring machines are an alternative to drilling and blasting (D&B) methods and "hand mining".
TBMs limit the disturbance to the surrounding ground and produce a smooth tunnel wall. This reduces the cost of lining the tunnel, and is suitable for use in urban areas. TBMs are expensive to construct, and larger ones are challenging to transport. These fixed costs become less significant for longer tunnels.
TBM-bored tunnel cross-sections range from 1 to 17.6 meters (3.3 to 57.7 ft) to date. Narrower tunnels are typically bored using trenchless construction methods or horizontal directional drilling rather than TBMs. TBM tunnels are typically circular in cross-section although they may be u-shaped, horseshoes, square or rectangular. [1] [2] [3] [4] [5] [6]
Tunneling speeds increase over time. The first TBM peaked at 4 meters per week. This increased to 16 meters per week four decades later. By the end of the 19th century, speeds had reached over 30 meters per week. 21st century rock TBMs can excavate over 700 meters per week, while soil tunneling machines can exceed 200 meters per week. Speed generally declines as tunnel size increases. [7]
The first successful tunnelling shield was developed by Sir Marc Isambard Brunel to excavate the Thames Tunnel in 1825. However, this was only the invention of the shield concept and did not involve the construction of a complete tunnel boring machine, the digging still having to be accomplished by the then standard excavation methods. [8]
The first boring machine reported to have been built was Henri Maus's Mountain Slicer. [9] [10] [11] [12] [13] Commissioned by the King of Sardinia in 1845 to dig the Fréjus Rail Tunnel between France and Italy through the Alps, Maus had it built in 1846 in an arms factory near Turin. It consisted of more than 100 percussion drills mounted in the front of a locomotive-sized machine, mechanically power-driven from the entrance of the tunnel. The Revolutions of 1848 affected the funding, and the tunnel was not completed until 10 years later, by using less innovative and less expensive methods such as pneumatic drills. [14]
In the United States, the first boring machine to have been built was used in 1853 during the construction of the Hoosac Tunnel in northwest Massachusetts. [15] Made of cast iron, it was known as Wilson's Patented Stone-Cutting Machine, after inventor Charles Wilson. [16] It drilled 3 meters (10 ft) into the rock before breaking down (the tunnel was eventually completed more than 20 years later, and as with the Fréjus Rail Tunnel, by using less ambitious methods). [17] Wilson's machine anticipated modern TBMs in the sense that it employed cutting discs, like those of a disc harrow, which were attached to the rotating head of the machine. [18] [19] [20] In contrast to traditional chiseling or drilling and blasting, this innovative method of removing rock relied on simple metal wheels to apply a transient high pressure that fractured the rock.
In 1853, the American Ebenezer Talbot also patented a TBM that employed Wilson's cutting discs, although they were mounted on rotating arms, which in turn were mounted on a rotating plate. [21] In the 1870s, John D. Brunton of England built a machine employing cutting discs that were mounted eccentrically on rotating plates, which in turn were mounted eccentrically on a rotating plate, so that the cutting discs would travel over almost all of the rock face that was to be removed. [22] [23]
The first TBM that tunneled a substantial distance was invented in 1863 and improved in 1875 by British Army officer Major Frederick Edward Blackett Beaumont (1833–1895); Beaumont's machine was further improved in 1880 by British Army officer Major Thomas English (1843–1935). [24] [25] [26] [27] [28] In 1875, the French National Assembly approved the construction of a tunnel under the English Channel and the British Parliament supported a trial run using English's TBM. Its cutting head consisted of a conical drill bit behind which were a pair of opposing arms on which were mounted cutting discs. From June 1882 to March 1883, the machine tunneled, through chalk, a total of 1,840 m (6,036 ft). [13] A French engineer, Alexandre Lavalley, who was also a Suez Canal contractor, used a similar machine to drill 1,669 m (5,476 ft) from Sangatte on the French side. [29] However, despite this success, the cross-Channel tunnel project was abandoned in 1883 after the British military raised fears that the tunnel might be used as an invasion route. [13] [30] Nevertheless, in 1883, this TBM was used to bore a railway ventilation tunnel — 2 m (7 ft) in diameter and 2.06 km (6,750 ft) long — between Birkenhead and Liverpool, England, through sandstone under the Mersey River. [31]
The Hudson River Tunnel was constructed from 1889 to 1904 using a Greathead shield TBM. The project used air compressed to 2.4 bar (35 psi) to reduce cave-ins. However, many workers died via cave-in or decompression sickness. [32] [33] [7]
During the late 19th and early 20th century, inventors continued to design, build, and test TBMs for tunnels for railroads, subways, sewers, water supplies, etc. TBMs employing rotating arrays of drills or hammers were patented. [34] TBMs that resembled giant hole saws were proposed. [35] Other TBMs consisted of a rotating drum with metal tines on its outer surface, [36] or a rotating circular plate covered with teeth, [37] or revolving belts covered with metal teeth. [38] However, these TBMs proved expensive, cumbersome, and unable to excavate hard rock; interest in TBMs therefore declined. Nevertheless, TBM development continued in potash and coal mines, where the rock was softer. [39]
A TBM with a bore diameter of 14.4 m (47 ft 3 in) was manufactured by The Robbins Company for Canada's Niagara Tunnel Project. The machine was used to bore a hydroelectric tunnel beneath Niagara Falls. The machine was named "Big Becky" in reference to the Sir Adam Beck hydroelectric dams to which it tunnelled to provide an additional hydroelectric tunnel.
An earth pressure balance TBM known as Bertha with a bore diameter of 17.45 meters (57.3 ft) was produced by Hitachi Zosen Corporation in 2013. [40] It was delivered to Seattle, Washington, for its Highway 99 tunnel project. [41] The machine began operating in July 2013, but stalled in December 2013 and required substantial repairs that halted the machine until January 2016. [42] Bertha completed boring the tunnel on April 4, 2017. [43]
Two TBMs supplied by CREG excavated two tunnels for Kuala Lumpur's Rapid Transit with a boring diameter of 6.67 m (21.9 ft). The medium was water saturated sandy mudstone, schistose mudstone, highly weathered mudstone as well as alluvium. It achieved a maximum advance rate of more than 345 m (1,132 ft) per month. [44]
The world's largest hard rock TBM, known as Martina, was built by Herrenknecht AG. Its excavation diameter was 15.62 m (51.2 ft), total length 130 m (430 ft); excavation area of 192 m2 (2,070 sq ft), thrust value 39,485 t, total weight 4,500 tons, total installed capacity 18 MW. Its yearly energy consumption was about 62 GWh. It is owned and operated by the Italian construction company Toto S.p.A. Costruzioni Generali (Toto Group) for the Sparvo gallery of the Italian Motorway Pass A1 ("Variante di Valico A1"), near Florence. The same company built the world's largest-diameter slurry TBM, excavation diameter of 17.6 meters (58 ft), owned and operated by the French construction company Dragages Hong Kong (Bouygues' subsidiary) for the Tuen Mun Chek Lap Kok link in Hong Kong.
TBMs typically consist of a rotating cutting wheel in front, called a cutter head, followed by a main bearing, a thrust system, a system to remove excavated material (muck), and support mechanisms. Machines vary with site geology, amount of ground water present, and other factors.
Rock boring machines differ from earth boring machines in the way they cut the tunnel, the way they provide traction to support the boring activity, and in the way they support the newly formed tunnels walls.
Shielded TBMs are typically used to excavate tunnels in soil. They erect concrete segments behind the TBM to support the tunnel walls. [45]
The machine stabilizes itself in the tunnel with hydraulic cylinders that press against the shield, allowing the TBM to apply pressure at the tunnel face.
Main Beam machines do not install concrete segments behind the cutter head. Instead, the rock is held up using ground support methods such as ring beams, rock bolts, shotcrete, steel straps, ring steel and wire mesh. [45]
Depending on the stability of the local geology, the newly formed walls of the tunnel often need to be supported immediately after being dug to avoid collapse, before any permanent support or lining has been constructed. Many TBMs are equipped with one or more cylindrical shields following behind the cutter head to support the walls until permanent tunnel support is constructed further along the machine. The stability of the walls also influences the method by which the TBM anchors itself in place so that it can apply force to the cutting head. This in turn determines whether the machine can bore and advance simultaneously, or whether these are done in alternating modes.
Gripper TBMs are used in rock tunnels. They forgo the use of a shield and instead push directly against the unreinforced sides of the tunnel. [7]
Machines such as a Wirth machine can be moved only while ungripped. Other machines can move continuously. At the end of a Wirth boring cycle, legs drop to the ground, the grippers are retracted, and the machine advances. The grippers then reengage and the rear legs lift for the next cycle.
A single-shield TBM has a single cylindrical shield after the cutting head. A permanent concrete lining is constructed immediately after the shield, and the TBM pushes off the lining to apply force to the cutter head. Because this pushing cannot be done while a next ring of lining is being constructed, the single-shield TBM operates in alternating cutting and lining modes.
Double Shield (or telescopic shield) TBMs have a leading shield that advances with the cutting head and a trailing shield that acts as a gripper. The two shields can move axially relative to each other (i.e., telescopically) over a limited distance. The gripper shield anchors the TBM so that pressure can be applied to the cutter head while simultaneously the concrete lining is being constructed.
In hard rock with minimal ground water, the area around the cutter head of a TBM can be unpressurized, as the exposed rock face can support itself. In weaker soil, or when there is significant ground water, pressure must be applied to the face of the tunnel to prevent collapse and/or the infiltration of ground water into the machine.
Earth pressure balance (EPB) machines are used in soft ground with less than 7 bar (100 psi) of pressure. It uses muck to maintain pressure at the tunnel face. The muck (or spoil) is admitted into the TBM via a screw conveyor. By adjusting the rate of extraction of muck and the advance rate of the TBM, the pressure at the face of the TBM can be controlled without the use of slurry. Additives such as bentonite, polymers and foam can be injected ahead of the face to stabilize the ground. Such additives can separately be injected in the cutter head and extraction screw to ensure that the muck is sufficiently cohesive to maintain pressure and restrict water flow.
Like some other TBM types, EPB's use thrust cylinders to advance by pushing against concrete segments. The cutter head uses a combination of tungsten carbide cutting bits, carbide disc cutters, drag picks and/or hard rock disc cutters.
EPB has allowed soft, wet, or unstable ground to be tunneled with a speed and safety not previously possible. The Channel Tunnel, the Thames Water Ring Main, sections of the London Underground, and most new metro tunnels completed in the last 20 years worldwide were excavated using this method. EPB has historically competed with the slurry shield method (see below), where the slurry is used to stabilize the tunnel face and transport spoil to the surface. EPB TBMs are mostly used in finer ground (such as clay) while slurry TBMs are mostly used for coarser ground (such as gravel). [46]
Slurry shield machines can be used in soft ground with high water pressure or where granular ground conditions (sands and gravels) do not allow a plug to form in the screw. The cutter head is filled with pressurised slurry, typically made of bentonite clay that applies hydrostatic pressure to the face. The slurry mixes with the muck before it is pumped to a slurry separation plant, usually outside the tunnel.
Slurry separation plants use multi-stage filtration systems that separate spoil from slurry to allow reuse. The degree to which slurry can be 'cleaned' depends on the relative particle sizes of the muck. Slurry TBMs are not suitable for silts and clays as the particle sizes of the spoil are less than that of the bentonite. In this case, water is removed from the slurry leaving a clay cake, which may be polluted.
A caisson system is sometimes placed at the cutting head to allow workers to operate the machine, [47] [48] although air pressure may reach elevated levels in the caisson, requiring workers to be medically cleared as "fit to dive" and able to operate pressure locks. [47] [48]
Open face soft ground TBMs rely on the excavated ground to briefly stand without support. They are suitable for use in ground with a strength of up to about 10 MPa (1,500 psi) with low water inflows. They can bore tunnels with cross-section in excess of 10 m (30 ft). A backactor arm or cutter head bore to within 150 mm (6 in) of the edge of the shield. After a boring cycle, the shield is jacked forward to begin a new cycle. Ground support is provided by precast concrete, or occasionally spheroidal graphite iron (SGI) segments that are bolted or supported until a support ring has been added. The final segment, called the key, is wedge-shaped, and expands the ring until it is tight against the ground.
TBMs range diameter from 1 to 17 meters (3 to 56 ft). Micro tunnel shield TBMs are used to construct small tunnels, and is a smaller equivalent to a general tunnelling shield and generally bore tunnels of 1 to 1.5 meters (3.3 to 4.9 ft), too small for operators to walk in.
Behind all types of tunnel boring machines, in the finished part of the tunnel, are trailing support decks known as the backup system, whose mechanisms can include conveyors or other systems for muck removal; slurry pipelines (if applicable); control rooms; electrical, dust-removal and ventilation systems; and mechanisms for transport of pre-cast segments.
Urban tunnelling has the special requirement that the surface remain undisturbed, and that ground subsidence be avoided. The normal method of doing this in soft ground is to maintain soil pressures during and after construction.
TBMs with positive face control, such as earth pressure balance (EPB) and slurry shield (SS), are used in such situations. Both types (EPB and SS) are capable of reducing the risk of surface subsidence and voids if ground conditions are well documented. When tunnelling in urban environments, other tunnels, existing utility lines and deep foundations must be considered, and the project must accommodate measures to mitigate any detrimental effects to other infrastructure.[ citation needed ]
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: CS1 maint: unfit URL (link)A tunnel is an underground or undersea passageway. It is dug through surrounding soil, earth or rock, or laid under water, and is usually completely enclosed except for the two portals common at each end, though there may be access and ventilation openings at various points along the length. A pipeline differs significantly from a tunnel, though some recent tunnels have used immersed tube construction techniques rather than traditional tunnel boring methods.
A slurry wall is a civil engineering technique used to build reinforced concrete walls in areas of soft earth close to open water, or with a high groundwater table. This technique is typically used to build diaphragm (water-blocking) walls surrounding tunnels and open cuts, and to lay foundations. Slurry walls are used at Superfund sites to contain the waste or contamination and reduce potential future migration of waste constituents, often with other waste treatment methods. Slurry walls are a "well-established" technology but the decision to use slurry walls for a certain project requires geophysical and other engineering studies to develop a plan appropriate for the needs of that specific location. Slurry walls may need to be used in conjunction with other methods to meet project objectives.
A tunnelling shield is a protective structure used during the excavation of large, human-made tunnels. When excavating through ground that is soft, liquid, or otherwise unstable, there is a potential health and safety hazard to workers and the project itself from falling materials or a cave-in. A tunnelling shield can be used as a temporary support structure. It is usually in place for the short-term from when the tunnel section is excavated until it can be lined with a permanent support structure. The permanent structure may be made up of, depending on the period, bricks, concrete, cast iron, or steel. Although modern shields are commonly cylindrical, the first "shield", designed by Marc Isambard Brunel, was actually a large, rectangular, scaffold-like iron structure with three levels and twelve sections per level, with a solid load-bearing top surface. The structure protected the men from cave-ins as they laboured within it, digging the tunnel out in front of the shield.
Drilling is a cutting process where a drill bit is spun to cut a hole of circular cross-section in solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed against the work-piece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the work-piece, cutting off chips (swarf) from the hole as it is drilled.
A drilling rig is an integrated system that drills wells, such as oil or water wells, or holes for piling and other construction purposes, into the earth's subsurface. Drilling rigs can be massive structures housing equipment used to drill water wells, oil wells, or natural gas extraction wells, or they can be small enough to be moved manually by one person and such are called augers. Drilling rigs can sample subsurface mineral deposits, test rock, soil and groundwater physical properties, and also can be used to install sub-surface fabrications, such as underground utilities, instrumentation, tunnels or wells. Drilling rigs can be mobile equipment mounted on trucks, tracks or trailers, or more permanent land or marine-based structures. The term "rig" therefore generally refers to the complex equipment that is used to penetrate the surface of the Earth's crust.
Drilling and blasting is the controlled use of explosives and other methods, such as gas pressure blasting pyrotechnics, to break rock for excavation. It is practiced most often in mining, quarrying and civil engineering such as dam, tunnel or road construction. The result of rock blasting is often known as a rock cut.
A modern core drill is a drill specifically designed to remove a cylinder of material, much like a hole saw. The material left inside the drill bit is referred to as the core.
Microtunneling or microtunnelling is a tunnel construction technique used to construct utility tunnels from approximately 0.5–4 m in diameter. Because of their small diameter, it is not possible to have an operator driving the tunneling machine, so they have to be remotely operated.
A roadheader, also called a boom-type roadheader, road header machine, road header or just header machine, is a piece of excavating equipment consisting of a boom-mounted cutting head, a loading device usually involving a conveyor, and a crawler travelling track to move the entire machine forward into the rock face.
The Kaimai Tunnel is a railway tunnel through the Kaimai Range in the North Island of New Zealand. Since it was opened in 1978, it has held the title of longest tunnel, at 8.879 kilometres (5.517 mi), in New Zealand, assuming this distinction from the previous title holder, the Rimutaka Tunnel. It is part of the Kaimai Deviation, which was constructed to bypass the old route of the East Coast Main Trunk Railway through the Karangahake Gorge.
Herrenknecht AG is a German company that manufactures tunnel boring machines (TBMs). Headquartered in Allmannsweier, Schwanau, Baden-Württemberg, it is the worldwide market leader for heavy TBMs.
Boring is drilling a hole, tunnel, or well in the Earth. It is used for various applications in geology, agriculture, hydrology, civil engineering, and mineral exploration. Today, most Earth drilling serves one of the following purposes:
The Inland Feeder is a 44 mi (71 km) high capacity water conveyance system that connects the California State Water Project to the Colorado River Aqueduct and Diamond Valley Lake. The Metropolitan Water District of Southern California designed the system to increase Southern California's water supply reliability in the face of future weather pattern uncertainties, while minimizing the impact on the San Francisco Bay/Sacramento–San Joaquin River Delta environment in Northern California. The feeder takes advantage of large volumes of water when available from Northern California, depositing it in surface storage reservoirs, such as Diamond Valley Lake, and local groundwater basins for use during dry periods and emergencies. This improves the quality of Southern California drinking water by allowing more uniform blending of better quality water from the state project with Colorado River supplies, which has a higher mineral content.
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Bertha was a 57.5-foot-diameter (17.5 m) tunnel boring machine built specifically for the Washington State Department of Transportation's (WSDOT) Alaskan Way Viaduct replacement tunnel project in Seattle, Washington, United States. It was made by Hitachi Zosen Sakai Works in Osaka, Japan, and the machine's assembly was completed in Seattle in June 2013. Tunnel boring began on July 30, 2013, with the machine originally scheduled to complete the tunnel in December 2015.
The Tuen Mun - Chek Lap Kok TBM otherwise known as Qin Liangyu or more formally, the Mixshield S-880 was the world's largest tunnel boring machine launched in June 2015 by Herrenknecht in Germany. The TBM was used to drill a 5 km tunnel connecting Tuen Mun to the Hong Kong International Airport, part of the Tuen Mun–Chek Lap Kok Link project. The cost of the tunneling machine itself was around HK$ 18.2 billion
Tunnels are dug in types of materials varying from soft clay to hard rock. The method of tunnel construction depends on such factors as the ground conditions, the ground water conditions, the length and diameter of the tunnel drive, the depth of the tunnel, the logistics of supporting the tunnel excavation, the final use and shape of the tunnel and appropriate risk management. Tunnel construction is a subset of underground construction.
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