EARTH PRESSURE BALANCED ( EPB )

NAT 2010 PORTLAND

SHORT COURSE
Presented by:
Dennis Ofiara
Chief Engineer

Solon, Ohio

PRESENTATION ITEMS

1. SHIELD MACHINE TYPE

2. OUTLINE OF EPB METHOD

3. EPB AND SLURRY SHIELDS

4. EPB SHIELD / STRUCTURE

5. SCREW CONVEYOR

6. ARTICULATION SYSTEM

7. BACKFILL

8. ADDITIVES

9. EPB OPERATION FLOW CHART

10. MUCK HAULAGE FOR EPB TUNNELS

1. SHIELD MACHINE TYPE

1-1 History

first shield

first shield

In England

under the sea

(manual)

(manual)

mechanical shield

EPB shield

slurry shield

EPB with foam

year
1825

1914

1950s

1960s

1970s

1980s

MARKET

First shield under Themes river

In 1825, Mr. Brunel developed shield tunneling method.
1. rectangular shield with 80 tons weight. Manual type.
2. Sectional area of 80 m2
3. segment was made from brick.

1-2 SHIELD MACHINE TYPE

open mode shield

(no bulkhead at cutting area)

Shield machine

partial open mode shield

manual shield
semi-mechanical shield
mechanical shield
Blind shield

(bulkhead with small opening)

Slurry shield

closed mode shield

(with bulkhead at cutting area)
bulkhead

shield

Excavation device
(under earth pressure)

segment
(no pressure)

soil discharge device

EPB shield

CLOSED MODE SHIELD

Blind shield (reference)

6.32m blind shield

1. soil is discharged from small opening,
2. only for very soft geology,
3. almost no demand nowadays,

Slurry shield

6.5m slurry

7.45m slurry

EPB shield

9.98m EPB

6.26m EPB

6.14m EPB

15.01m EPB

Slurry shield explanation of features

Slurry keeps stability.

Lower torque

Lower thrust

To slurry treatment
plant on the surface

Less cutter wear

Difficult for gravel discharge

USE JAW CRUSHER

Slurry volume and density control by

discharge pump, considering advance speed

2. OUTLINE OF EPB METHOD

2-1 Earth pressure control by soil
EPB PRINCIPLE: DISCHARGED VOLUME PROPORTIONAL
TO SHIELD ADVANCE TO MAINTAIN EARTH PRESSURE
SHIELD
ADVANCE m3

BULK HEAD

DISCHARGE

ADDITIVE

VOLUME m3

EARTH PRESSURE
(SOIL + WATER)

AGITATOR

MUMUCK CHAMBER

EARTH PRESSURE SENSOR

OPERATIONS
1. Fill excavated soil in muck chamber.
2. Inject additives in order to improve muck fluidity.
3. Rotate cutterhead to agitate muck and additives, and push thrust cylinders.
4. Control discharged muck volume by adjusting screw conveyor speed to meet excavation volume.
5. Monitoring earth pressure sensors on bulkhead.

2-2 Features of EPB method

1. Versatility for wide range of geology;
By selecting proper additives, EPB method can be applied for wide range of geology.
Large sized gravel is also excavated and discharged by screw conveyor.

2. Totally economical method, generally;

Excavated soil can be normally disposed as it is (in case of foam type EPB).
As slurry plant or equivalent large facilities is not necessary, total tunnel construction
cost is generally less than other methods like slurry method.
3. High stability of surface ground;
Geology is basically supported by excavated soil with additives, which brings less
settlement of surface ground.
4. Simultaneous back fill;
As muck chamber and surrounding area of shield skin plate are filled with soil,
simultaneous back filling is easier, which contributes to better stability of surface ground.
5. Space of launching shaft area;
Construction site for launching shaft can be minimized compared with slurry method,
which is suitable in city area shaft.

3. EPB AND SLURRY SHIELDS

application of geology

Particle diameter (mm)

clay

silt

EPB

SLURRY

A
B
C
D
E
F

fine coarse small mid big

cobble
sand
gravel

--- most suitable

--- suitable
--- not suitable

EPB is better for

Slurry is better for

Totally economical method

Excavating in gravel geology

Excavating under river or sea

Smaller space on surface

Excavating under high pressure

EPB shield explanation of features

Excavated soil keeps stability.

Larger cutter wear

Possible for gravel discharge

Higher torque

Higher thrust

Earth pressure control by screw speed and

gate opening ratio, considering advance speed

Summary of EPB and Slurry

shield type
summary

SLURRY

EPB
advantage

advantage

1.Economical system in total

(TBM is more expensive, but
no surface plant.)

1. Suitable for excavation

under high underground
water pressure

2. Available for gravel

excavation

2. Less wear of cutting tools

and steel structure.

3. Smaller surface space

is required.

3. Smaller TBM power

--- torque and thrust force
(TBM is cheaper.)

4-2 Main components

shield

: circular steel plate main body, which supports inside space from outside earth pressure

When articulation is applied, it is divided into front- and rear shields.

cutter head
: rotating parts with cutting tools on front surface, which excavates the ground.
tail seal
: seal to stop soil and water invasion at the end of rear shield
muck chamber
: the space between cutter head and bulk head, which is filled with excavated soil.
thrust cylinder
: hydraulic cylinders which are arranged circumferential area of shield and push machine to
advance forwards.
screw conveyor : soil discharge device, rotated by motors.
screw gate
: open/close gate of muck, located at the end of screw conveyor
erector
: assembling device of segments, while gripping, rotating and positioning a segment one by one.
articulation cylinder: hydraulic cylinders which connect front shield and rear shield.
rotary joint
: supplying device of hydraulic oil, additives, etc. from font shield (stationary) to
cutter head (rotating).
CHS
: Cutter Head Support ,cutter head drive unit with main bearing, cutter head drive motors, etc.
segment feeder : supplying device of segments to erector
back up gantries : a series of mounting structures which accommodate back up devices such as cabin,
power units, electrical devices ,belt conveyor, additive device, backfill device, etc.
connection bridge : connecting structure between shield and back up gantries.
bulkhead
: pressure wall to separate pressurized area and non-pressurized area

4. EPB SHIELD / STRUCTURE

Typical EPB structure, with articulation, shaft screw, and spoke type cutterhead
cutter drive motor
shield

articulation cylinder
screw conveyor

bulk head
cutterhead

cutters
Screw gate

tail seal
erector
pedestal

thrust cylinder
muck chamber

SIMPLIFIED FORCES ACTING ON EPB SHIELD

REPRESENTATIVE LOADS SHOWN FOR 5m TBM AT 4 bar MAXIMUM PRESURE
POSSIBLE SURFACE LOADS
(BUILDING, OTHER STRUCTURES)
EARTH + WATER
PRESSURE

SKIN DRAG = 400t

SEAL DRAG
JACKING FORCE
2500t INSTALLED

TOWING
FORCE
NET
800t

C HEAD
TORQUE
2500t

80t

TBM
WEIGHT
190t

SEAL DRAG
SKIN DRAG TBM WEIGHT
90t

SHIELD BODIES
HIGHLY LOADED STRUCTURAL ELEMENTS
LARGE AND HEAVY PIECES
CAN BE SPLIT TO SIMPLIFY TRANSPORT AND ASSEMBLY

CUTTERHEAD DRIVE STRUCTURE

Cutter chamber (Soil & Water)
Forward shield body
Grease cavity
Grease purge line
Cutter main seal

Drive pinion

Cutter drive unit

Main bearing

Main Seals : 4 lip seal x 3 sets / ( inside +

outside )
Bearing housing

Sealing Pressure : 1.0 MPa

Lubricant cavity
Coolant cavity
Cutter drum
Cutterhead support

Lubrication : Automatic grease lubrication

system
Cooling: Water cooled

Main Bearing must have extreme capacity to sustain very

high loading and provide necessary reliability

Bullgear
gear
Bull

A
Seal
Seal

Outer race
THRUST

Retainer
Retainer

Roller
Roller
Innerrace
race
Inner

A
VIEW A - A

CUTTERHEAD DRIVE SYSTEM

drive type
Summary

ELECTRICAL MOTOR

HYDRAULIC MOTOR

1.High total efficiency, 90-95%

1. Low efficiency, 65%

2. Little maintenance

2. High maintenance is required for

oil contamination, temperature,
leakage, etc.

3. Larger space is necessary for

installation.
4. Speed control needs additional
device (VFD, pole change, etc.).

3. Smaller space is necessary for

installation.
4. Speed control is easy.

CHS torque
CHS torque is calculated from experimental formula.

CHS torque : T (kNm) = a x D^3

D : shield diameter
(m)
a : torque coefficient (- )
(alpha value)
In case of EPB,
a is selected between (20-25).
in case of slurry, (15-20).

rotary torque (kNm)

35000

Installed cutter drive torque data (EPB)

30000
25000
20000

15000
10000
5000
0
0

2000

4000

6000

8000

10000

12000

14000

16000

shield diameter (mm)

CUTTERHEAD TYPES

1. OPEN SPOKE TYPE CUTTERHEAD

Spoke type cutterhead

1. opening ratio --- approx. 55%
2. mainly applied for
stable geology, or
soft geology

OPEN SPOKE TYPE CUTTERHEAD

Cutter head

Opening ratio ; 55%

High torque; =22.3
High thrust 32,000kN
Speed: 1.5min-1

Agitating bar (fixed)

Protection of soil clogging
Agitating bar (rotating)

Fish tail

Foam injection

Soil mixture / conditioning

CUTTERHEAD TYPES

2. PLATE TYPE CUTTERHEAD

Water injection

Plate type cutterhead

1. opening ratio --- approx. 30-35%
2. mainly applied for

unstable geology, or mixed (hard)

geology ,or large gravel geelogy
Additive injection port

2. PLATE TYPE CUTTERHEAD

Cutter head

Opening ratio :29%~60%

High torque: =29.8
High thrust: 1500 8000 t
Speed: 0-1.5-3.0 rpm

Agitating bar (fixed)

2 positions
Agitating bar (rotating)
3 positions
Foam injection
5 - 10 positions

Protection of soil clogging

Soil mixture / conditioning

CUTTERHEAD
(1) Cutting tools

cutter bit
(for soil)

disc cutter
(for rock)

bolt-on type cutter bit

pin type cutters bit
welded type cutter bit
fish tail (center cutter)
pilot bit
knife edge bit
special knife edge bit
side protection bit
flapper protection bit
wear detector bit
single disc
twin (double) disc

SOFT GROUND CUTTING TOOLS

Pin type cutter bit

Functions
1. cutting
2. scraping soil into chamber

SOFT GROUND CUTTING TOOLS

Bolt on type
cutter bit

Bolt on type
cutter bit

SOFT GROUND CUTTING TOOLS

Special knife edge bit

SOFT GROUND CUTTING TOOLS

Knife edge bit

Side protection bit

Pilot bit

SOFT GROUND CUTTING TOOLS

Flapper protection bit

Wear detector
Fish tail (center cutter for soil)

(hydraulic type)

Hydraulic piping

SOFT GROUND CUTTING TOOLS

(2) Copy cutter
extended and retracted during rotation
copy cutter

spoke
Overcut area

Copy cutter is installed in cutter spoke,

and is hydraulically extended and
retracted during rotation.
.
Copy
cutter is used to excavate outer
area of cutter head in order to make
curve excavation easy.

CUTTERHEAD

DISC CUTTERS FOR ROCK, BOULDER, MIXED FACE

EXCAVATION

Single disc, back loading

Twin disc, back loading

CUTTERS SEEN FROM INSIDE CUTTERHEAD STRUCTURE

MIXED FACE CUTTERHEAD WITH DISC CUTTERS

Assembled Cutterhead view

6.26m EPB for Chengdu metro, china

Cutter bit material & wear

It is necessary to estimate cutter wear and make a proper plan of cutter bit replacement.
(brazing)

MATERIALS
chip --- tungsten carbide (WC) + cobalt (Co),
hardness : Hv 1000-1100 level (JIS E5)
shank ---SCM440H(JIS),Q345(GB), 42CrMo(EN),etc.
WEAR LIFE , estimation
wear : a (mm) = K (wear coefficient) x L (travelling length)

chip

shank

CUTTER BIT

wear coefficient K, (mm/km) , in case of EPB based on chip material of E5

for clay/silt K = 0.005-0.015, ave. 0.010
sand
K = 0.015-0.025, ave. 0.020
gravel K = 0.025-0.040, ave. 0.033
travel length L (km) = pai x De/1000 x N x (Lo / V x 1000000 ), at most outside cutter bit
De : excavation diameter (m)
N : cutterhead rotary speed (rpm)
Lo : tunnel length (km)
V : advance speed (mm/min)

Hard facing

Cutterhead diameter
Cutterhead diameter is decided to overcut a shield diameter a little larger

CUTTING DIAMETER OF CUTTER HEAD

Basically, cutting diameter has to be always larger than
shield diameter.
Generally, it is designed as follows.
In case of soil excavation,
Cutting diameter (at outside cutter bit )
De = Ds + 2 x (15-20) mm (for 6-10 m class EPB)
In case of rock excavation,
Cutting diameter (gage disc cutter )
De = Ds + 2 x (25-30) mm (for 6-10 m class EPB)

CUTTERHEAD

De

SHIELD

Ds

SHIELD THRUST JACKS

MUST PROVIDE NEEDED THRUST, PLUS RESERVE
MUST SAFELY HOLD SEGMENTS DURING RING BUILD
CAN PROVIDE SOME TORQUE REACTION
MUST BE COMPATIBLE WITH SEGMENT RING DESIGN: KEY INSERTION, KEY
LOCATIONS, RING ROTATION, SEGMENT JOINT LOCATION
MUST SPREAD LOAD EVENLY TO SEGMENTS TO PREVENT DAMAGE
MUST HAVE ADEQUATE STROKE FOR RING BUILD, REBOUND, STEERING

SHIELD THRUST JACKS

THRUST JACKS AND JACKING SHOES MUST

BE COMPATIBLE WITH SEGMENTS

Crack

Segment gasket groove too close to edge; no reinforcement.

Shield thrust
Shield thrust is calculated from experimental data, geological condition, etc.
unit thrust (kN/m2)
1800

Thrust depends on geology, earth

pressure, water pressure, shield
advance speed, etc.
Generally in case of EPB,
Unit thrust (F) is selected ;
F=1100-1200kN/m2
(in case of slurry, 1000-1100kN/m2)

Installed unit thrust data (EPB)

1600
1400
1200
1000
800
600
400
200

0
0

2000

4000

6000

8000

10000

12000

14000

shield diameter (mm)

16000

MAN LOCK

2 Chamber

Sub chamber

Main chamber

SEGMENT ERECTOR

Hydro. Motor

Slide jack

Lift jack

Support jack A

Support jack B

SEGMENT ERECTOR MECHANICAL PICKUP

SEGMENT ERECTOR VACUUM PICKUP

5. SCREW CONVEYOR

ONE
PITCH

MAINTAINS PRESSURE IN CUTTER CHAMBER

PRESSURE DROP PROPORTIONAL TO NUMBER OF PITCHES AND SCREW TYPE
VOLUME / PRESSURE CONTROL AT DISCHARGE VIA GUILLOTINE GATE, ROTARY DISCHARGE VALVE,
PISTON DISCHARGER ETC.
SCREW SIZE DETERMINES POSSIBLE RATE OF ADVANCE
SCREW SIZE LIMITED BY BEARING / DRIVE ASSEMBLY AND OTHER MECHANICAL ELEMENTS

SCREW CONVEYOR
(1) Screw conveyor type

inspection
window

hydraulic motor (direct drive)

screw
shaft

screw gate (bottom)

Screw
blade

screw
casing

screw conveyor with shaft

hydraulic motor (outside drive)

screw gate (back

end)

ribbon screw

screw conveyor with ribbon screw

Photos of screw conveyor

SHAFT TYPE SCREW CONVEYOR

RIBBON SCREW

SCREW CONVEYOR RIBBON TYPE

WEAR PROTECTION ACCORDING TO GEOLOGICAL CONDITIONS

Pressure drop along screw length

Pressure drop ; delta P=0.02 to 0.03 Mpa/pitch

screw conveyor length L

soil
screw gate

Screw length
P1=0

earth pressure P1

ADJUST ROTARY SPEED, DISCHARGE

OPENING, AND ADDITIVES TO CONTROL
PRESSURE DROP

SCREW CONVEYOR RIBBON TYPE

HIGH TORQUE DRIVE SYSTEM

screw conveyor
P

APPROX 0.2 BAR

PER FLIGHT

O/
M

screw with shaft

R/G

SHAFT TYPE SCREW CONVEYOR,

normal type

casing

gate

BOULDER
DISCHARGE

O/
M

ribbon screw

R/G

RIBBON TYPE SCREW CONVEYOR,

In case of large gravel with low pressure

casing

gate

inspection window

O/
M

screw with shaft

ribbon screw

MIXED TYPE SCREW CONVEYOR,

In case of large gravel with high pressure

casing

gate

R/G

screw conveyor numbers

SINGLE SCREW CONVEOYR

DOUBLE SCREW CONVEOYR

No2 screw
No1 screw

No1 screw
spherical joint
gate

Applications
1. in case of high earth pressure geology,
2. in case of non-belt conveyor transportation applied,

gate

MIXED TYPE SCREW CONVEYOR

DISCHARGE

MIXED TYPE CONVEYOR

MID
GUILLOTINE
GATE

MIXED TYPE SCREW CONVEYOR

INSPECTION DOOR
FOR LARGE
BOULDER REMOVAL

ACCESS DOOR
FOR BOULDER
REMOVAL BOX

6. ARTICULATION SYSTEM

Front shield

Rear shield

Articulation jack

Articulation seal

Articulation for Curved Tunnels

ARTICULATION

ACTIVE ARTICULATION

PASSIVE ARTICULATION

SKID EFFECT

Fa

F out

Fa

F in

Thrust cylinders are installed on rear shield

in parallel direction. Articulation cylinders connect front- and rear
shields.

Thrust cylinders are installed on front shield.

Thrust cylinders are installed on front shield.

Articulation cylinders connect front- and rear shields.

Steering is easier.
Thrust cylinders push segment ring evenly,
which reduces segment damage.
(segment preferably receives even thrust loads.)
Articulation force is approx. 70-80% of thrust.

Steering is harder.
Thrust cylinders push segment ring unevenly.
(segment receives partial thrust loads.)
Articulation force is approx. 50% of thrust.
(cylinder cot is low)

Rear push type

Tail clearance is even.

(curve direction)
Pushing paralell to segment
Large steering moment

No tail clearance difficult to assemble segments

Front push type

Segment moves outside.

Inclined cylinder angle to segment

(curve direction)

Small steering moment

Inside cylinder(s), not be pushed.

TYPE OF ARTICULATION

Front shield

Rear shield

Passive Articulation system

Thrust cylinder. pushes the front
shield.
Front shield
Rear shield

Active Articulation system

Articulation cylinder. pushes the
front shield.

TAIL SEAL
CRITICAL TO PREVENT GROUNDWATER OF GROUT FROM
INFILTRATING SHIELD BODY
BRUSH TYPE SEALS AND THICK GREASE MAKE SEAL
Tail skin plate

Segment

Lubrication line for each space

Annual Space

TAIL SEAL
GREASE

Tail seal (Brush type) , 3 rows

(1)

Automatic tail seal lubrication system controlling order, time, volume

(2)

Every annual space between tail seal having injection ports

4-2-1 shield (skin plate)

(1) how to decide shield diameter
Tail clearance and skin plate thickness should be properly selected in order to reduce tail void and backfill grouting for better
surface stability and economy.
Shield O.D ; Db = segment outside diameter(Ds) + 2 x (tail clearance(x) + skin plate thickness(t) )
normal tail clearance ; x = 25mm, for 4- 6m class EPB,
= 40mm, for 9-10m class EPB,

normal skin plate thickness ; t =60-100mm

(depending on strength, backfill piping design, etc.)
BACKFILL GROUT COST
APPROX $200/m3
BACKFILL ANNULUS VOLUME

(backfill piping of approx. 40mm, others)

Tail skin plate thickness : t

Tail clearance : x
Tail skin plate

SEGMENT

Tail seal (25-28mm)

Shield outside diameter : Db

SEGMENT

Segment outside diameter : Ds

7. BACKFILL
To fill the circular gap between shield and segment perfectly is very important for surface stability and
segment fixing.
backfill injection device

GL

backfill grouting

tail void

SEGMENT
CUTTER HEAD

SHIELD

shield diameter D

segment diameter d

backfill theoretical volume (tail void): Q = pai * (D^2 - d^2 ) / 4 x length

Normally, backfill grouting device has 130% injection ratio ( = injection volume / tail void x 100 (%) )
Two kinds of injection control method are available --- (1) volume control and (2) pressure control.

One liquid (mortar) and two liquid grouting

There are two types of backfill grouting---one liquid type and two liquid type
.

Schematic / one liquid type

TAIL SKIN PLATE

TAIL VOID
SEGMENT

back fill device

power board

flushing line

mortar pump
x

back fill device

control panel

back fill device

control panel

SEGMENT

back fill device

control board
mortar tank

reciever tank

Schematic / two liquid type

mixing nozzle
TAIL SKIN PLATE

TAIL VOID
SEGMENT

flushing line

SEGMENT

back fill device

power board

back fill device

control board
x x
back fill device
valve control
board

mortar tank
x

mortar pump

acceralator tank
acceralator
pump

back fill device

control panel

reciever
tank

Comparision
one liquid (mortar) and two liquid grouting
Comparison table Mortar grouting and Two-liquid grouting
(1)

Item
Strength

One liquid (mortar) Grouting

More than 20Mpa can be achieved
(28days)

Two liquid Grouting

2-3Mpa (28 days)

Less than 12 hours

More than 24 hours (A liquid)

Difficult to control

20 sec or less, 1 hour or later

can be rheologic.

(2)

Usable time
(After
batching)

(3)

Gel time

(4)

Setting Time

Very long, very difficult to stabilize

lining, easy to occur segment gap,
flotation.

1 hour or later, can hold lining

effectively

(5)

Volume Loss

Depend on filling condition, less

than 3%

Very little, less than 5%

(6)

Segregation

Easy to segregate with underground

water

No segregation

(7)

Fillingness

Poor with low pressure, partial

pressure on lining, with ground
water cause flotation force.

Very well with low pressure,

provide unique pressure on
lining

(8)

Ring Stepping
and floatation

Easy to happen stepping on lining joint,

Floatation is also easy to happen.

Minor
stepping
evident
generally good tunnel.

but

(9)

Grout
transportation

Mixing at surface and delivered by

pressured pipe line to
No delivery time risk (Sunday, Night
shift) as the material delivery can
be managed during normal hours

(10)

Cleanup

Cement mortar grout delivered by

outside batching plant and hence
delivery
to
be
managed.
Grout loading and transport required in
tunnel. Transfer required on TBM from
grout car to front tank with extra
blockage risk.
Extensive cleanup of grout car, transfer
pump, transfer line, grout tank on trailer
1 and grout pumps.

(11)

Grout mixing
quality

Grout delivery variability by supplier, on

site plant also not easy to control.
Mixing with manual control pump is not
uniform.

Mixing procedure controlled

computer system.
Uniform quality no breaching.

(12)

On site
handling

Labor intensive relatively for transfers

and manual recording

No manual mix control operation

required.
Computerized operation Automatic
record (volume, pressure, time etc)

Reduced cleanup.

Line cleaning twice daily for type

A line using pig.

by

(13)

Grouting port
Grout pump

Normally required more than 4nos, 2

pump. Depend on TBM diameter

(14)

Loss time risk

Mixing nozzle blockage

solved with mix change

(15)

Trouble record

Many trouble record reported

(16)

Material
availability

problem

Normally required 2nos, 1 pump.

Depend on TBM diameter.

Mixing nozzle
happen

blockage

may

No trouble report more than 25

years

Depend on the country, necessary

material is not easy to get with
standard quality.

Any country necessary material is

easy to get with standard quality.

(ref) TAC*1 two liquid system

two liquid type, located outside of tail shield
height is approx. 100mm (incl. cover plate.)

B liquid line

Hydraulic cylinder

A liquid line

flushing line

*1 ---- Japanese backfill device supplier

Mixing nozzle

TAC backfill grouting system

Operation details
Backfill injection
liquidline
line
B Bliquid

A liquid line

Mixing nozzle

Backfill injection

Flushing line

Piston, operated by hydraulic

cylinder

Line flushing
A liquid line

B liquid line

Flushing line

8. ADDITIVES

Generally speaking, excavated soil cannot transmit earth pressure evenly and properly
as it has not sufficient fluidity.
Therefore, it is necessary to inject additives (foam or bentonite, others) so as to improve
soil fluidity.
Improved soil makes it possible to keep accurate and even earth pressure in muck
chamber, and also easier transportation through screw conveyor while reducing earth
pressure inside of screw conveyor.
bentonite
Additive type
foam

Each additive has each calculation method according to actual geological conditions.

Effect of foam injection

Injection 10%

Injection 25%

Injection 15%

Injection 30%

Injection 20%

Injection 40%

(2) Foam injection

Arrangement of foam injection port (sample)
Injection port

FEATURE OF FOAM INJECTION

<advantage>
1. Foam can reduce stickness of soils,
which will bring smooth soil movement and
less cutter head and screw rotary torque.
2. Foam can improve muck fluidity of wide
range of soils with high sealing performance.
3. Foam , as air characteristics, has a
damper effect of earth pressure.
4. Foam disappears in some period of time,
which makes it easy to handle muck
disposal.
5. Foam device is compact.
<mixing ratio (rough value)>
clay
35% (to reduce stickness)
silt
20%
sand 30%
gravel 65%(to increase fluidity)

Emisor 8.89m EPB , 12 ports applied

FOAM GENERATION

Air Compressor

Additive tank

Water tank

Mixing tank
Foam Generator

Foam Generator

Foam Generator

FEATURE OF FOAM INJECTION

Improve the fluidity of excavated muck by the

bearing efficiency of foam.
Improve the waterproof of excavated muck by
replacing the water by foam between soil grains.
Prevent the sticking of excavated muck on
cutterhead and chamber.
Improve the working environment.

9. EPB OPERATION FLOW CHART

EPB EXCAVATION CONTROL
CALCULATION OF THEORITICAL EARTH PRESSURE

SETTING OF EARTH PRESSURE P0

GROUND STABILITY,
EARTH PRESSURE WHEN TBM STOPS.

SETTING OF THRUST CYLINDER SPEED AND

SCREW CONVEYOR ROTARY SPEED

EXCAVATION

P1>P0
INCREASING SCREW SPEED,

P1<P0
EARTH PRESSURE
P1

DECREASING ADVANCE SPEED

DECREASING SCREW SPEED,

INCREASING ADVANCE SPEED

P1=P0
large torque
INCREASING ADDITIVE

small torque

CUTTERHEAD
TORQUE

DECREASING ADDITIVE

normal
not good
CHARACTERISTICS
NOTES
P0 ; target earth pressure for excavation
P1 ; actual earth pressure

CONFIRMATION OF MUCK
CHARACTERISTICS, DENSITY,
QUANTITY, ETC.

OF MUCK ?
good
DISCHARGING MUCK,
CONTINUE EXCAVATION

10. MUCK HAULAGE FOR EPB TUNNELS

RUBBER TIRE VEHICLES OR MINE TRAINS
(CYCLIC SYSTEM, BUT NOTE THAT RING BUILT
TIME PROVIDES SOME TIME FOR THE HAULAGE
CYCLE)
PUMPING, SLURRY SYSTEMS (CONTINUOUS
SYSTEM)
CONTINUOUS CONVEYOR SYSTEM
(CONTINUOUS SYSTEM)

MUCK HAULAGE FOR EPB TUNNELS

RUBBER TIRE VEHICLES
CYCLIC
USEFUL FOR STEEP GRADES
FEASIBLE FOR SHORT TUNNELS
FEASIBLE FOR LARGER TUNELS WHERE A
ROADWAY IS BEING CONSTRUCTED
SIMULTANEOUSLY AND THERE IS ROOM FOR
TRUCKS TO PASS
DIESEL POWER REQUIRES EXTRA VENTILATION
USEFUL TO HAUL IN SEGMENTS AND OTHER
MATERIALS

MUCK HAULAGE FOR EPB TUNNELS

RUBBER TIRE VEHICLES

MUCK HAULAGE FOR EPB TUNNELS

MINE TRAIN HAULAGE

CYCLIC
LIMITED TO 2-4% GRADE MAXIMUM
CAN GENERALY PASS TRAINS IN SMALL
TUNNELS. CAN BE SUITABLE FOR LONG
TUNNELS WITH SWITCHES
DIESEL POWER REQUIRES EXTRA VENTILATION
USEFUL TO HAVE IN SEGMENTS AND OTHER
MATERIALS

MUCK HAULAGE FOR EPB TUNNELS

MINE TRAIN HAULAGE

MUCK HAULAGE FOR EPB TUNNELS

MUCK CAR HAULAGE

Muck

improved by injecting additives

Bentonite
Polymers
Large quantities of additives
were required

TAMPA WATER PROJECT

Alafia River Crossing
ROBBINS EPB TBM SS84-302

MUCK HAULAGE FOR EPB TUNNELS

PUMPING AND SLURRY SYSTEMS
CONTINUOUS SYSTEM (EXCEPT DURING PIPE
ELONGATION)
USEFUL FOR STEEP GRADES, UP SHAFTS
CAN CONTAIN HIGH WATER FLOWS AND H2S
OR OTHER GASSES LIBERATED AT THE FACE
CLEAN

MUCK HAULAGE FOR EPB TUNNELS

PUMPING AND SLURRY SYSTEMS

Grizzly hopper at screw

conveyor discharge

TAMPA WATER PROJECT

Alafia River Crossing
ROBBINS EPB TBM SS84-302

MUCK HAULAGE FOR EPB TUNNELS

PUMPING AND SLURRY SYSTEMS

Slurry pump at shaft bottom

TAMPA WATER PROJECT

Alafia River Crossing
ROBBINS EPB TBM SS84-302

MUCK HAULAGE FOR EPB TUNNELS

CONTINUOUS CONVEYOR SYSTEM

CONTINUOUS SYSTEM
RAPID PRODUCTION RATES
USEFUL FOR STEEP GRADES (STEEPER THAN
RAIL HAULAGE)
GRADE LIMITED BY MATERIAL CONSISTANCY,
WATER
REDUCED DIESEL FUMES, TUNNEL
VENTILATION REQUIREMENTS ARE REDUCED.

MUCK HAULAGE FOR EPB TUNNELS

CONTINUOUS CONVEYOR SYSTEM

MUCK HAULAGE FOR EPB TUNNELS

CONTINUOUS CONVEYOR SYSTEM

Lower NW Interceptor (LNWI)

4.6 m (15 ft) EPB
Two 610 m (2000 ft) river
crossings at 6% downgrade
First soft ground TBM tunnel
with continuous conveyor

MUCK HAULAGE FOR EPB TUNNELS

CONTINUOUS CONVEYOR SYSTEM

Specially designed continuous

conveyor with sealed transfer
points and conveyor wash box

MUCK HAULAGE FOR EPB TUNNELS

CONTINUOUS CONVEYOR SYSTEM
Vertical storage

MUCK HAULAGE FOR EPB TUNNELS

CONTINUOUS CONVEYOR SYSTEM
Conveyed Material

MUCK HAULAGE FOR EPB TUNNELS

CONTINUOUS CONVEYOR SYSTEM

Wash Box

END OF PRESENTATION