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World Tunnel Congress 2008 - Underground Facilities for Better Environment and Safety - India

Soft ground excavation of the Brezno tunnel

Matous Hilar
D2 Consult Prague s.r.o., Czech Republic
Jaromir Hert
Metrostav a.s., Czech Republic
Roman Smida
Sudop Praha a.s., Czech Republic

SYNOPSIS : A requirement to relocate the railway line section between towns Brezno and Chomutov in
Northern Bohemia was caused by intention to extend the surface lignite mine Libous. 7.1 km long relocated
railway section required a single track tunnel construction. The Brezno tunnel with its length 1758 m is the
longest railway tunnel in the Czech Republic. Construction of the shallow tunnel started using the Pre-
vaulting method in 2000. A tunnel excavation was realised predominantly in plastic clays and claystones
covered by several metres of quaternary deposits. The area was affected by previous undocumented mining
activities. Complicated geological conditions caused many difficulties which resulted in significant collapse
in 2003. The collapse occurred when about 860m of the primary tunnel lining was completed. A decision has
been made to complete remaining (including excavations re-excavation of the collapsed area) using
Sequential Excavation Method (SEM) with sprayed concrete lining. All excavations including a re-
excavation of the collapsed area were completed in 2006. The tunnel was opened for traffic in April 2007.

1. INTRODUCTION claystone with an addition of coal. The Libkovice


Member, which forms the immediate cover of the
The Brezno tunnel construction was funded by the deposit, has the character of monotonous pelitic
Severočeské doly, a.s. (the North-Bohemian Mining sediments. In terms of geology, three layers can be
Company) together with the SŽDC s.o. (Czech distinguished within them, i.e. a brown bituminous
Railway Authority). The main tunnel contractor was claystone layer, grey claystone without a
Metrostav a.s., the tunnel designer was SUDOP montmorillonite layer and a grey monotonous
Praha a.s. French company BEC Freres s.a. worked claystone layer. The quaternary cover consists of
on project as the Pre-vaulting method (PM) fluvial sandy-gravelly sediments, diluviofluvial and
guarantor. The monitoring and evaluation of diluvial sandy/clayey-sandy wash loams. The
geological conditions was provided by SG quaternary sediments form the cover throughout the
Geotechnika a.s. The company IKP Consulting tunnel length, with a varying depth up to 6m.
Engineers s.r.o. was present on site as the consultant Results of the site investigation indicated that
for the main contractor from 2004, while D2 the tunnel will be constructed in very difficult
Consult Prague s.r.o. was engaged on site as a geotechnical conditions of the environment
client’s technical assistance and supervisor from consisting of finely grained, medium to highly
2005. plastic clays with transitions to firm claystone. The
stability of ground in the excavated opening was
2. GEOLOGY anticipated to be significantly affected by the
arrangement of discontinuity surfaces, their
The tunnel was driven through upper parts of the smoothness, density and jointing. The occurrence of
Holešice and Libkovice Members, which are sliding zones, creating difficult to very difficult
covered by quaternary sediments. The upper part of construction conditions, was expectable in the
the Holešice Member is represented by the brown weakened portal areas. No mining activities were
coal deposit itself. The non-coal intermediate layer proven along the tunnel route by the survey before
consists of an alternation of silty claystone and the commencement of the construction works.

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Subsequently, during the construction, the expected into 14m long boreholes were used for the ground
conditions had to be confirmed or disconfirmed by a stabilisation. They were installed into the tunnel
supplementary survey executed directly from the face and around the tunnel. Important part of the
tunnel. ground improvement activities was the grouting of
old mine workings through radial 6m long
3. PRE-VAULTING METHOD OF rockbolts. Despite of maximum efforts to improve
EXCAVATION the condition of old mine workings prior to the
execution of the prevault old mine workings
A decision to use the Pre-vault Method (PM) for the
partially filled with debris or only partially
excavation and primary lining construction of the
consolidated were encountered. Therefore cavities
tunnel was done by the client, the condition to
exceeding the ideal profile of the prevault
utilise this method was part of the contract. The
(extending to the tunnel cross-section or having the
excavation using PM started in March 2002.
form of extensive overbreaks) had to be filled with
Application of sprayed concrete for the PM
sprayed concrete. Once the excavation under the
was a special technical problem. Sprayed concrete
completed prevault had been completed, the
forming the pre-vault represents also the primary
sprayed concrete found inside the tunnel profile had
lining structure supporting the excavation until the
to be removed. In two cases, the tunnel tube even
cast-in-situ final lining is finished. The PM
passed through a vertical mine working. The longest
principle is such that a 20 cm-wide slit (for the
old mining working which was encountered
Brezno tunnel) is cut along the upper and side parts
(including the timbering) at the excavation face was
of a pre-defined tunnel circumference. Step by step,
perpendicular to the tunnel centre line and it ran
simultaneously with cutting of the prescribed
across the whole tunnel profile width. The necessity
number of its segments in prescribed sequence, the
of the tunnel geomonitoring for the safe execution
slit is filled with sprayed concrete. Hardened
of the primary lining was confirmed. In some areas
concrete forms a protective pre-vault reaching
additional measures had to be adopted as
ahead of the rock excavation. The pre-vault has a
improvement grouting in area of the primary lining
shape of a truncated cone, which shape allows
feet, additional installation of 6 – 8m long radial
overlapping of individual pre-vaults. The chain saw
anchors, installation of 60cm thick concrete bracing
length determines the length of the pre-vault which
beams in invert or closure of invert by sprayed
was 5 m in the case of the Brezno tunnel. The pre-
concrete lining.
vault can overlap the preceding prevault from 2.5 to
Due to rapid closing of the ground around pre-
0.5 m (the excavation advance length is selected
cut slits, it was impossible to follow the original
according to geological conditions encountered,
technological procedure and the procedure had to be
from 2.5 to 4.5 m). Full-face excavation takes place
adjusted within accepted specifications. The slot
then under the protection by the pre-prepared
could not be cut in one go, but a system of sticking
primary lining. Unusually long pre-construction
the 85cm wide cutting jib of the pre-vault tunnelling
testing of sprayed concrete for PM has been carried
machine into the excavation face with “intermediate
out prior start of construction.
rock pillars” left between each cut had to be
The first section (km 1.242 to km 1.550) was
adopted. The “pillars” were removed and replaced
intensely undermined by previous coal mining
with sprayed concrete subsequently. This procedure
activities. The excavation performance was quite
was applied to the initial 130m of the tunnel
slow during the learning period, when the
excavation. In those conditions, one pre-vault
contractor’s crews became familiar with a new
consisted of 16 partial segments. With improvement
tunnelling method. Unfortunately originally
of excavation conditions the number of segments
unexpected significant occurrence of unregistered
could be reduced up to five. The original time of 16
mine workings was regularly encountered in the
to 20 hours for the cutting and filling of the slot was
tunnel profile and its vicinity. Old mine workings
reduced up to 7 to 8 hours.
were found mainly within the 2.3m-thick upper coal
In the beginning, there was a significant
seam. The encountered coal seam gradually dipped
problem with the filling of the 5m long and 20cm
under the tunnel bottom. The ground ahead and
wide slot with s sprayed concrete; it was an entirely
under the excavation was improved by high-
new phenomenon in the execution of primary liners
pressure grouting. Also fibreglass dowells inserted
in the Czech Republic. Generally this meant to

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Figure1. Perforex 3713 prevault tunnelling machine

abandon all common experience with sprayed invert had to be closed by sprayed concrete lining
concrete gained on NATM tunnels and to gradually with lattice girders. All pre-vaults with accelerated
gather new know-how for proper filling of the slots. increase of deformations were closed. Concurrently
The machine used for the PM was a Perforex 3713 with the installation of inverts the feet of the pre-
pre-vault tunnelling machine (Fig.1). The machine vaults were stabilised by grouting. Eventually, the
was deployed in the so-called verification operation pre-vaults were anchored to the surrounding ground
mode, which was ordered by the Czech Bureau of (8 rockbolts per one pre-vault). A decision was
Mines with the aim of verifying its properties in the made to build 80m of the final invert, because all
Czech Republic. No significant defects of this attempts to keep deformations under prescribed
equipment causing significant downtimes occurred limits failed. The deformations of the pre-vaults
during the excavation. Minor defects were removed totally cease after the final invert installation. The
during the course of the verification operation. monitoring limits were exceeded; the maximum
Another important machine was a PG – 115 drilling transverse and vertical convergences reached 72mm
rig, which was used for drilling of 16m-long and 96mm respectively. The probable cause of such
boreholes from the tunnel face. Due to geological a significant deformational response was a weak
conditions the drilling was done by screw drills zone found in the ground between km 1.950 and
without water flush. 1.975.
The second section (km 1.550 to 1.920) was a The fourth section (km 2.030 to km 2.106) was
section where the geotechnical conditions complied a section with no significant anomaly expected from
with expected behaviour, they were significantly the site investigation, stable ground conditions were
better in comparison to the first section. expected. The site investigation predicted the
Geotechnical conditions allowed tunnel excavation presence of unweathered, firm and only locally
with advances 4.5m. The advance rates reached fractured claystone, with the shear strength above
almost 100m per month. No modifications of the 200 kPa. The primary lining consisting of pre-vaults
original design were required. All deformations without the invert was expected to be stable.
stayed within expected limits. However the tunnel excavation encountered
Excavation of the third section (km 1.920 to weathered, densely jointed soft claystone with shear
km 2.034) started in the beginning without strength below 100 kPa. With the experience
problems. However at the beginning of March 2003 obtained from the previous section, a prevault type
deformations started to rapidly grow and the allowing the 4.0m excavation advance was selected,
excavation had to be suspended. The primary lining with ten 6.0m long radial rockbolts on each pre-

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vault. Because the moderate increments of encountered in the condition which had been
deformations of the pre-vault 178 did not stabilise, anticipated by the survey, the corresponding shear
the lengths of the radial anchors were increased to strength would be sufficient for the tunnel stability
8m. The deformations did not cease. Thus the to be maintained. The investigation, which was
length of the prevaults was reduced to 3.0m and carried out by the Regional Bureau of Mines in
eight 6m-long radial anchors were added. Most concluded that the tunnel collapse was caused
During the common site inspection carried out by a loss of the bearing capacity of the foundation
on 2.5.2003 in the presence of all parties, the base under the primary liner due to an abrupt
condition of the primary lining in the tunnel and the change in geotechnical parameters.
results of convergence measurements available
were checked and it was stated that everything was 4. SEQUENTIAL EXCAVATION METHOD
developing without problems. No obvious signs of
the future development of deformations were found. Prior to the decision about the completion of
Nevertheless, a decision was made that the final the tunnel, many technical and technological
invert has to be installed throughout the length of problems had been solved. A solution had to be
the tunnel section between the pre-vaults from km found for legislation and the design associated with
2.002 to km 2.028. the tunnel construction and, at last but not least,
Monitoring results started to grow, thus closure even for the funding of the works. The tunnel
of pre-vaults started earlier than expected. The construction was significantly delayed and there
supporting frames were successfully erected under was a threat that the entire project would not be
two pre-vaults and the erection of the frame under finished on time and the progress of the open cast
the third prevault started. Despite the efforts to mine operations would be suspended. After
support problematic places by steel frames, the complicated negotiations among involved parties
development of deformations was so rapid that and after the execution of a supplementary site
there was no chance to stop it. On the 5 May 2003 investigation, the client decided to complete tunnel
at about 5 am, the tunnel lining collapsed at a length excavation from the opposite portal. The new
of nearly 85m, burying the Perforex 3713 pre-vault design based on the results of the supplementary
tunnelling machine. The propagation of the primary site investigation was carried out. The new design
lining collapse stopped at the last closed pre-vault. proposed the use of Sequential Excavation Method
Surprisingly the deformations prior collapse stayed (SEM) for the initial 62m of the drive and a
within the limits set by the design, with the modified Pre-vaulting Method (PM) for the
moderate increment of maximum 1.0 to 2.0mm per remaining 552m. The modification meant
day, but without tendency to stabilise. For that installation of the lattice girders, steel meshes and
reason, a decision was made, based on the sprayed concrete around the whole tunnel profile
experience gained at the previous section that the immediately after the prevault exposure.
structure has to be closed by the invert once the In his effort to guarantee the tunnel
deformation values would reach 27 to 30mm construction by the modified PM, the client
vertically or 22 to 24mm horizontally. instructed the contractor to order a second pre-vault
Important for the collapse was that instead of tunnelling machine. The order was placed and the
the expected firm, unweathered claystone the machine was supplied in parts. The assembly of
excavation encountered layers of heavily weathered machine was finished at the end of 2004. The
claystone intensely jointed with the consistency design of SEM and PM excavations took into
softer than expected. This geology was not consideration the previous tunnelling experience
anticipated. As a result of this geological anomaly, and new geotechnical data. All structures of the
the shear strength of the ground dropped below primary and secondary linings were significantly
expected values used in design. Testimony of reinforced.
eyewitnesses of the collapse development as well as The SEM construction started in September
the subsequent structural analyses confirmed that 2004. Again it had to cope with very difficult
the collapse happened due to the loss of the tunnel geotechnical conditions, which were accompanied
subbase stability. The stability of tunnel subbase by the instability of the face. The SEM excavation
directly and unequivocally depends on the value of was adjusted to these conditions. The tunnel was
the shear strength. If the claystone layer had been excavated using the canopy tube umbrellas. The

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tunnel face was divided into three parts – the top and evaluated. Realised study showed that
heading, bench and invert. The primary lining of the application of the PM method would mean an
tunnel consisted of sprayed concrete, steel mesh, extension of the construction time and increase in
lattice girders, radial steel anchors, the invert was the cost. Therefore client instructed the contractor to
closed. The tunnel face was supported by sprayed continue with SEM. The contractor had to assess
concrete coat and by fibreglass face dowels (Fig.2). the geology every 20m of the tunnel length with
The face stability was improved in some cases by respect to the consideration of the possibility to
further sequencing and by a supporting ground utilise the modified PM method.
wedge in centre. A significant element contributing Such the situation came around after the
to the tunnel excavation stability was a rapid closure excavation of about 350m of the tunnel by the SEM.

Figure 2. Installation of fibreglass face dowels during SEM construction

of the tunnel profile. The contractor agreed that the deployment of the
In the initial about 290m long section, the pre-vault tunnelling machine was viable, but the
tunnel excavation passed through a quarrying Regional Bureau of Mines (RBM) in Most did not
claystone. The limited stability ground formed recommend to use the second pre-vault tunnelling
overbreaks at the top headings despite the fact that machine. It was therefore subsequently decided that
the overburden was supported by micropiles and the the tunnel excavation be finished using the SEM. In
top heading was divided into 6 parts. Despite the three cases a large overbreaks SEM excavation
significant increase in the number of longitudinal further developed in minor collapses. The
face dowels, the stability of the face consisting of excavation was completed in October 2006, when
slickensided fragments of clayey ground did not tunnel was holed into a shaft, which had been
improve. The excavation was suspended by the constructed in advance.
client at chainage km 2.659 (62m from the exit
portal). The client required start of the modified PM 5. ESCAPE SHAFT CONSTRUCTION
method. This method was not recommended by
other involved parties. On the client’s request the Changes in engineering legislation took place
design of improvement measures to allow the during the Brezno tunnel construction. The today
modified PM method application was carried out commonplace safety equipment of long tunnels was

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not required at the time when the individual stages building is 29.9m. The shaft does not have to be
of the design documents were developed and equipped with an emergency lift. The final lining of
submitted for approval. When the tunnel was being the escape shaft is made of C 25/30 - grade
designed after the collapse of the lining consisting reinforced concrete. In terms of fire safety, the shaft
of the pre-vaults, the project owner decided to structure with the staircase is an independent fire
respond to the new situation. On his instruction, a compartment.
new assessment of the Fire Design of the Březno
tunnel was carried out. The assessment resulted in a 6. RE-EXCAVATION OF THE COLLAPSED
requirement for an escape exit. The circular shaft SECTION
lined with piles, which was designed to allow the
recovery of the Perforex machine, was used for the The recovery of the 85m long section collapsed in
construction of the escape route. This circular shaft May 2003 was another complicated task. 22m of the
was built at chainage km 2.095 320 (the shaft centre primary lining were completely filled with soft
chainage), with the centre set 1.5m off the tunnel ground which flew from the collapsed section, 63m
centre line. The position of the shaft was selected of the primary lining fell down. Several alternatives
with the aim of „encircling“ the buried Perforex of the collapse recovery procedure were considered.
machine. The diameter of the shaft, measured to the Finally selected mined variant included an escape
centres of the piles, was 21m and the depth shaft which was also used for the recovery of the
amounted to 35m. The shaft lining consisted of 70 buried Perforex machine (Fig.3). The
pieces of secant piles 1180mm in diameter, drilled commencement of the work was delayed by
at 0.942m spacing. The deflection of the vertical negotiations with the insurance company. The
during the pile drilling was lower than 1%. The negotiations were concluded in December 2005 and
shaft lining was reinforced by four massive the works commenced in January 2006. A slushy
reinforced concrete walers, 8 pieces of 30cm thick ground had been removed form the initial 22m long
and 1.0m high reinforcing sprayed concrete rings section and original primary lining was supported
and two 10.8m high reinforced concrete supporting by additional sprayed concrete lining with closed
walls, which were built in the bottom part of the invert.
shaft. Under the protection of the shaft reinforced in The recovery of the remaining 63m of the
the above-mentioned way, the buried Perforex pre- collapse started with the construction of 7 pile walls
vault tunnelling machine was exposed and lifted up. drilled from the surface in perpendicular direction
The shaft received the tunnel from both sides, i.e. to the tunnel centre line with 9m spacing (Fig.4).
from the side of the dissipated collapse and, The walls formed independent, 8m long sections
subsequently, from the exit portal side where the (chambers) of the collapsed tunnel. There were,
tunnel was excavated by SEM. The casting of the naturally, some fears prior the commencement of
final lining, which had been till that time carried out the excavation in the collapse area regarding the
concurrently with the excavation, was completed deformational behaviour of the rock mass which
with a delay. A stair shaft, which was built above had been deformed in the area of the tunnel profile
the final lining block number 87, was connected and above the tunnel by the previous accident. For
through a safety recess with the entrance to the that reason it was decided that core probe holes be
escape exit from the tunnel. The entry to the escape drilled ahead of the face before the commencement
route from the tunnel is from the emergency of excavation of each particular section and further
walkway level, through a 1800mm wide fire double decisions made on the extent of the rehabilitation
door, which opens to the staircase space. From this work necessary. A decision was made before the
point it is possible to ascend on three 2000mm commencement of the excavation beyond the first
wide, geometrical, atypical stair flights above the dividing pile wall that horizontal jet grouted
tunnel tube. From this level, the staircase continues columns be carried out within the tunnel cross
by straight flights through a rectangular shaft. The section to strengthen the rock mass. This measure
ratio of rise and tread is 34.7°, which means that the was also used beyond the third dividing pile wall.
staircase is of a common design. The staircase is The excavation in the other compartments did not
provided with handrails on both sides. The require this strengthening.
difference between the emergency walkway level in The crown of the tunnel was regularly
the tunnel and the level of the floor of the surface protected by means of canopy tube pre-support. The

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Figure 3. Pile walls and shaft designed for recovery of collapsed tunnel section

Figure 4. Pile wall with installed micropile umbrella

drilling for the pre-support was carried out from the out above the excavated cross section. However, the
front side of each pile wall. The tubes were always execution of jet grouting in the tunnel overburden
tailed into the next pile wall (they bridged the entire stopped after the completion of the excavation of
distance between neighbouring dividing walls). the initial three compartments, similarly to the jet
Efforts were made in the beginning to embed the grouting within the tunnel profile.
canopy tubes into jet grouted columns to be carried

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The excavation proceeded in steps of 1m in the cohesive clay or claystone. The attempt to
advance per cycle. The excavation was supported drill through the jet grouted columns for installation
by steel mesh, lattice girders and sprayed concrete. of the pre-support tubes was similarly little
In the beginning, efforts were made to immediately successful. We can state that the jet grouting carried
close the temporary invert of the top heading. out within the tunnel profile acted rather as pressure
Naturally, in terms of structural analysis, it would grouting. The cement grout filled various fissures
have minimised the lining deformations. On the and empty spaces in the collapse rubbles. The
other hand, this requirement logically meant that highest accumulation of the grout was found at the
full-face top heading excavation was necessary. beginning of the excavation, under the preserved
With regard to the stability problems of the face and pre-vault created by the Perforex machine. Because
the danger to workers at the excavation face, it was of the relatively favourable consistency of the
decided that the temporary top heading invert was mostly cohesive material – the collapse rubble, and
to be closed later (i.e. at a distance of 2 - 3m). This with respect to the fact that stabilisation of cohesive
measure made the stabilisation of the face by means soils by jet grouting is a difficult task, it was
of the rock wedge, which was left in the centre of decided after the excavation of the third section to
the top heading, possible. This measure showed to abandon the idea of the stabilisation by jet grouting.
be a suitable compromise. In addition to the rock
Conversely, the canopy tube pre-support with
wedge, the excavation face was regularly stabilised
the tubes tailed into the pile walls can be evaluated
by a thin layer of sprayed concrete. When more
very positively; the canopy certainly contributed to
intense manifestations of instability were
the improvement of stability and safety (Fig.5). The
encountered, the top heading excavation and
top of the excavation face above the rock wedge
application of sprayed concrete face was divided
collapsed several times during the excavation.
into several steps. The excavation of the bench and
However, owing to the tubes, the instability had
tunnel bottom followed the top heading excavation
never extended above the completed canopy. At the
at a distance exceeding 9m.
beginning of the excavation, the ends of the pre-
The effect of the jet grouting rather fell short support tubes got overloaded due to the stability
of expectations. The jet grouted columns which had problems of the face. As a result, the first lattice
been expected to reinforce the ground, were girder under the canopy was deformed. This
perceivable only in the non-cohesive Quaternary problem was successfully removed by means of
material; unfortunately, they were not much visible doubling the first lattice girder under the canopy

Figure 5. Re-excavation of collapsed area using canopy tubes

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tube pre-support (inside the compartments) and 3. Hilar, M. – John, V. “Recovery of the collapsed
welding of the ends of the tubes through the steel section of the Brezno tunnel”. Tunel 3/2007.
mesh to the last BTX lattice girder before the 4. Polak, P. “Sprayed concrete in traffic tunnel
dividing wall (i.e. above the tubes). construction”. Tunel 3/2004.
5. SUDOP PRAHA a.s. “Tunnel Brezno – detailed
The original schedule for the collapse recovery documentation“. 2000 – 2006.
assumed 12 months of works. Despite complicated
ground conditions some supporting measured could BIOGRAPHICAL DETAILS OF THE AUTHORS
be reduced during excavation and also the Dr. Matous Hilar graduated in civil
construction period could be shortened to 8 months. engineering from the Czech Technical
University in 1997, he completed PhD
7. CONCLUSION in tunnelling at the Czech Technical
University in 2001. Four years he
Construction of the Brezno tunnel was one of the worked for Mott MacDonald Ltd. in
most complicated excavations of underground UK. From 2006 he works as senior
structures in the Czech Republic. During engineer for D2 Consult Prague s.r.o.
construction a very significant range of tunnelling He is chartered civil engineer in the CR
and UK. He was involved in tunnels for Terminal 5 at
and ground improvement techniques had to be
Heathrow in UK, SMART in Malaysia, CrossRail in UK,
employed. The construction required the and Czech tunnels Mrazovka, Brezno or Prague - Beroun.
cooperation with a large number of professionals
Ing. Jaromir Hert graduated from the
including international experts. An experience and a VSB - Technical University of
know-how gained during the construction are Ostrava in 1987. from 1987 to 1999
certainly very valuable for all participants. Despite he worked in mining industry in the
all problems and time delays during the Czech Republic. From 1999 is
implementation of the project, the deadline for the employed by Metrostav a.s. as a
relocated railway line operation (April 2007) set by leader of various projects. He was
the client was finally met. It is also necessary to involved in tunnel Mrazovka in
emphasize that no major injury was registered Prague, he was a chief site manager
during the Brezno tunnel construction.
during the Brezno tunnel construction.
Ing. Roman Smida graduated in civil
The first author is grateful for the financial engineering from the Transport and
support by the research grant GACR 205/08/0732. Infrastructure University of Zilina in
1973. In 1973 he joined SUDOP
REFERENCES PRAHA a.s. as a consultant. From
1980 to 2003 he was a director of the
1. Bartak, J. et al. “Underground construction in the tunnelling department. He
Czech Republic”. Satra, Prague, 2007. participated on many tunnelling
projects in the Czech Republic, he
2. Hert, J. “Brezno tunnel construction”. Tunel 4/2007. was a chief consultant of the Brezno tunnel.

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