Shaft/Portal Design &

Construction

Glenn M. Boyce, PhD, PE

Principal
September 12, 2018
Got Requirements?
• What is the purpose of the tunnel – water,
wastewater, transit, highway?
• Shaft (vertical) versus portal (horizontal)
• Start and end points
• Ground conditions (soil or rock)
• Groundwater
• Temporary or permanent
• Does it house anything?
Shafts
• Circular versus
rectangular?
• Rectangular shafts
need bracing and struts
• Figure 8
• Elliptical
• Snowman
• Watertight?
No
internal
support
needed
for
circular
shafts
Location
• Available land or Open space
• Staging areas
• Access
• Room for support equipment
• Existing utilities
• Consider noise, vibration, dust, and fumes
Design Considerations
• Temporary vs. permanent
• Size to effectively perform work
• Excavation support method
• Groundwater control
• Pressures on support systems
• Thrust resistance and openings
• Launch and entry requirements
Project Layout
• Use shafts for multiple tunnel drives
• Use for multiple purposes
• Maximize distance for access to practical
limits
• Depth is typically controlled entry and exit
flow requirements
• Determine shaft size based on tunnel size
• Locate where there is access
Groundwater Control
• Dewatering (lower water)
– Well points
– Eductor well point system
– Deep wells
• Physical barriers (keep out)
– Use watertight system with internal sump pumps
– Ground freezing
– Groundwater cut-off grouting
Additional Concerns
• Overhead wires
• Traffic/access
• Employee parking
• Wheel wash
• Muck disposal
• Contamination ground
• Water treatment
Working Space
Shaft/Portal Size and Equipment
Shaft/Portal Size
• Launch, Receive, Access
• Circular, rectangular, or other shape
• Frames, utilities, stairs, vents
• Pipe, segments, initial support
• Space for welding/connections/handling
• Spoil handling, rail, belts, supplies
• Ancillary equipment – pumps
Shaft/Portal Types
• Launching or
Jacking
• Receiving
• Intermediate
• Access
• Drop
• Rescue or 9-1-1
Support Systems
Shoring Factors
• Soil and/or rock conditions
• Groundwater conditions
• Groundwater control requirements
• Available construction staging area
• Depth
Support Methods
• Steel sheet piling
• Soldier piles and
lagging
• Secant piles
• Drilled shafts
Support Methods
• Liner Plate
• Caissons
• Ground
freezing
• Slurry walls
• Soil mixing
 Shaft Support Systems
GROUND
TYPE SIZE AND SHAPE DEPTH WATERTIGHT REMARKS
TYPE
Trench boxes and Any size (width only limited
20 ft Most soils No Used above groundwater; short installation time
speed slide rails by internal bracing)

Soldier Piles and wood Any size (width only limited Used above groundwater; limited cantilever depth;
60 ft Any No
lagging (or steel plates) by internal bracing) sequential excavation and lagging installation
Typically used above groundwater; requires
50 to
Soil Nailing Generally non-circular
60 ft
Most soils No specialized equipment; sequential excavation, used
for portals
Soil with
Liner plates Any size (+/- 30 ft dia.) 100 ft
stand-up time
No Flexible; adaptive to various sizes; can be expensive

Conventional excavation 1000+ ft

Any size (+/- 25 ft dia.-
(deep),
with rock dowels and deep)
200 ft
Rock No Used in constructing mine shafts
shotcrete (+/- 40 ft dia- shallow)
(shallow)
Most soils (but
Can be reused; inexpensive; used below
Any size (width only limited trouble in
Sheet piles by internal bracing)
50 ft
cobbles and
Yes groundwater; limited by crossing utilities; pre-drilling
required in rock or bouldery ground
boulders)
Most soils and
Secant piles Circular (+/- 35 ft diameter) 110 ft
weak rock
Yes Easy to build; limited by crossing utilities
Most soils and High cost; requires specialized equipment; limited by
Drilled shafts Circular (+/- 30 ft diameter) 200 ft
weak rock
Yes
crossing utilities
Similar to slurry walls; specialized equipment;
Cutter soil mixing Any size (+/- 35 ft diameter) 90 ft All soils Yes
generates heat with cement
Any size Specialized equipment; expensive; limited by
Slurry walls (+/- 135 ft diameter)
200 ft All soils Yes
crossing utilities
Difficult to freeze moving water or saline-rich water;
Ground freezing Any size (+/- 35 ft diameter) 200 ft Most soils Yes
high energy costs; allows flexible layouts and shapes

Typically part of the permanent works; can be used

Caissons Any size (+/- 30 ft diameter) 130 ft Most soils Yes
below water table; limited by crossing utilities
Soldier Piles
Advantages Disadvantages
• Sequential excavation • Use above
and lagging installation groundwater
• Piles installed before • Limited cantilever
excavation depth
Secant Piles
Advantages Disadvantages
• Water tight • Limited depth
• Common equipment • Consider more costly
• Easy to build
• Best used for circular
shafts
Secant Pile Construction
• Step 1:
Install secant
piles
• Step 2:
Jet grout base to
cutoff
groundwater
• Step 3:
Jet grout for
shaft break-
ins/out
• Step 4:
Excavate
Drilled Shafts
Advantages Disadvantages
• Fast installation • High cost
• Simple excavation • Special equipment
and support • Limited diameter size
• Usable in cohesive • Limited by crossing
soils utilities
Sheet Piles
Advantages Disadvantages
• Work in most soils • Noise and vibration to
• Can be reused install
• Inexpensive method • Limited by crossing
• Used below utilities
groundwater • Require lifting devices
Liner Plate
Advantages Disadvantages
• Flexible • Expensive
• Adaptable to various • Requires adequate
sizes standup time to install
Caissons
Advantages Disadvantages
• Water tight • Expensive
• Can be part of • Specialized work
permanent works • Needs to sink evenly
• Can be used below
water table
Ground Freezing
Advantages Disadvantages
• Installation requires • Requires several
drill rig months time
• Allows shaft in • Difficult to freeze
unstable ground moving water
• Requires water or • Increase secondary
saturation effects
• High energy costs
Slurry Walls
Advantages Disadvantages
• Similar to secant piles • Specialized equipment
• Depths exceeding • Expensive
200 feet • Limited by crossing
• Constructible in all soil utilities
types
Slurry Wall Construction
Soil Mixing
Advantages
• Similar to slurry walls
• In-place excavation and
mixing
• Constructible in all soil
types
Disadvantages
• Specialized equipment
• Expensive
• Not clean
Shoring Methods
• Sloped excavations
• Trench boxes
• Soil nailing and shotcrete
• Soldier piles and lagging
• Steel sheet piles
Sloped Excavations
Advantages
• Simple excavation
• No special equipment
• No lining material
• Utilize any equipment
• Construction can begin immediately
• Not limited by crossing utilities
Sloped Excavations
Disadvantages
• Larger footprint – 2H:1V excavation for most soils
• Use only above groundwater
• Use for shallow depths
• Cannot be adjacent to existing structures
• Increased crane capacity
Trench Boxes
Advantages Disadvantages
• Work in most soils • Limited by crossing
• Can be reused utilities
• Short installation time • Require lifting devices
• No noise or vibration • Use above
groundwater
Soil Nailing & Rock Dowels
Soil Nailing
Advantages Disadvantages
• Sequential excavation • Expensive
• Can drain away • Use above
hydrostatic pressures groundwater
• Specialized equipment
Portals with Soil Nails & Shotcrete
Excavation Sequences
Portals
Invert Preparation
Invert Preparation
• Groundwater present
• Soft bottom
• Tremie plug
• Concrete slab
• Sump pump
• Permanent works
Breakouts and Launches
Wall Seals
• Groundwater
• Ground behavior
• Slurry system
• Lubrication
• Backfill grouting
• Jet grouting outside supports
Entry
Ring
Seal
Jet Grouted Break-outs
Jet Grouting
Hole Through
Build-outs
Connections
Finishes
Closing Thoughts
• Do we need portals or shafts?
• How many are needed?
• Where is the groundwater table?
• Is the shaft in dry or wet ground?
• How deep is the shaft?
• What shaft methods have been used in the area
before?