Week 13 Tunnel 457.308 Construction Methods and Equipment Department of Civil and Environmental Engineering Seoul National University Prof. Seokho Chi shchi@snu.ac.kr 건설환경공학부 35 동 304 호
Tunnel Project Planning Consideration Ground condition avoids unstable grounds and locations that experienced any disaster Economical construction and safety during construction Efficient maintenance facility for ventilation and lighting, emergency control Traffic management and riding quality Sustainability: Harmony with ambient natural environment
Tunnel Project Planning 평면선형 지반조건이양호하고유지관리가용이하며주변환경에미치는영향이적은곳을통과하도록결정 편압이예상되거나습곡지역 / 용출수가많을것으로판단되는지역, 안정성이우려되는단층및파쇄대지역등은피하도록함. 터널앞 / 뒤로접속하는구간을포함한전체적인선형을유지하고운전자의심리적인폐쇄감과압박감을고려하여평면선형은가능한직선으로계획 종단선형 공사중이나개통후의주행안정성, 환기, 방재설비등을종합적으로고려하고차량의주행안전성이확보되는완만한경사로함. 터널개통후에터널내부의용수를종단배수구에의하여자연유출시키려면 0.1% 이상의경사가필요 시공중에발생하는용수의자연배수를위해서용수가적은경우에는 0.3%, 상당히많은경우에는 0.5% 정도의경사가필요 종단경사를지나치게크게하면시공중의버력처리나자재운반등의작업능률이떨어지고개통후에도교통용량이저하되므로 0.3-2% 의완만한경사를가지도록함.
Tunnel Project Planning 터널간의상호간격 2개이상의병렬로터널을계획하는경우에는터널의단면형상, 치수, 시공법, 시공시기등을검토하여상호간격을결정 일반지반 : 중심간격을굴착폭의 2배정도 연약지반 : 중심간격을굴착폭의 5배정도 터널갱구부 갱구의위치는공사용설비의배치, 공사용도로의설치, 사토장, 공사용전력의확보와장래의유지관리등을고려하여선정 갱구부는경사면과인접하고토피가얇아서불안정한곳이므로갱문은비탈면의최대경사각과직교하거나비탈면의활동이없는안정한지반에설치 비탈면의붕괴, 낙석, 토석류, 홍수, 눈, 안개등의불리한위치에갱구를설치하는경우에는갱구부의안정성검토와방재설비를고려하여위치선정
용출수 : 주변의암반절리면에서흘러들어오는물 Tunnel Project Planning 터널의단면 구조적으로안정하고양수압에대하여유리굴착면적이커서비경제적이고굴착시공이어려움 구조적으로안정하고양수압에도안정하며원형보다경제적마제형보다굴착량이큼 굴착시공성이양호, 여굴량이적어서경제적구조적으로불리, 양수압에도불안정 Maintenance access( 검사원통로 ): consider the location of utility conduit and emergency access, 1m from road surface and min 0.75m width for safety, 2m pass height Facility free zone( 시설한계 ): obstacle free zone for traffic safety, larger than 4.8m Road width: same to connected roads Pipe utility conduit( 공동구 ): conduit for electricity, fireplug, drainage pipe, etc. Drainage: for gushout water, surface water, waste water 측방여유폭 : road edge to free zone, same to road shoulder, min 1m for highway, if less than 2m for 1,000m or longer tunnel, need to equip with emergency parking space every 750m (emergency, accident vehicles) Equipment space( 시설대 ): for lighting, emergency equipment
Tunnel Project Planning Cross Section for Ventilation Channeling: Install duct systems considering tunnel length, ventilation volume Jet fan: 0.2m from the facility free zone, Normally hanging to the ceiling, hanging distance = 0.5 of the fan diameter Emergency Access Emergency path( 피난연결통로 ): (1) path connecting multiple tunnels or the tunnel and emergency tunnel, (2) doors should be smoke protected, fire protected, and non-powered, (3) set up every 250m, bigger one for emergency vehicles every 750m, every 300m for the tunnel less than 1,200m length Emergency tunnel( 피난대피터널 ): (1) tunnel for evacuation (parallel, vertical) connected with emergency paths, (2) provide air, pressurized facility to protect smoke inflow Emergency shelter( 피난대피소 ): (1) equipped with emergency lights, telephone, fireplug, CCTV, battery
Tunnel Excavation Excavation Equipment Power Shovel Widely used, Easy for loose earth, Slow for hard earth Power Breaker Wide applicability, Slow speed, Noise and vibration 발파굴착 : economical, easy construction, vibration, noise, performed with other equipment operations 파쇄굴착 : (1) static: expansion by gas pressure cracking breaker/backhoe, (2) dynamic: frequent impact surface expansion Road Header Rotating cutter header, Mucking( 버력 ) reduce muck loading time, Many consumption of picks for hard earth, Lots of dust require ventilation, sprinkling Tunnel Boring Machine TBM, Rotating and mucking, Open TBM for rocks (reaction to tunnel walls) and shield TBM for soil and weathered rocks (self powered)
Tunnel Excavation Excavation Method Total Cross Section Excavation ( 전단면굴착 ) Hard earth condition (self-bearing) Small/medium-size cross sections Simple and fast operation with equipment Early stabilization( 응력재배치 1-cycle 완료 ), clean tunnel face( 막장 ) Difficult to earth risk management, delay on shortcreting/ rockbolting, need big working platform Bench Cut ( 수평분할굴착 ) Large cross section Long bench (digging depth, 파들어가는길이 ): > 3D (or 50m), hard earth conditions Short bench: 1D (or 10m) < bench < 3D, normal earth Mini bench: < 1D, soft earth Multi bench: 3 or more benches, unstable earth conditions
Tunnel Excavation Excavation Method Bench Cut ( 수평분할굴착 ) Temporary Invert ( 가인버트 ): for medium/large cross sections, excavate long bench while temporarily shotcreting above the bench for deeper excavation (provide larger working areas), not economical considering shotcreting and curing time Ring cut: leave supporting 2-3m core to tunnel face pressure and excavate, soft/poor earth, reduced and limited working areas
Tunnel Excavation Excavation Method Vertical Cut ( 중벽 / 연직분할굴착 ) When top earth condition is weak and the large cross section does not have bearing capacity, Temporary supports like rock bolts or shotcrete, 1D~2D Side Pilot Drifting ( 선진도갱굴착 ) For very large cross sections, excavate while checking earth and underground water conditions, Set early bearing capacity, Water drainage through side pilots 측벽도갱으로굴착면을미리보강 터널안정확보, 배수용이
Tunnel Excavation Excavation Method Blasting Drilling Set up Survey Blasting Rock Bolt Ventilation Finishing Mucking
Tunnel Excavation Excavation Method Blasting Method V Cut Center Cut Slope Center Cut Pyramid Cut Blasting Method 심발발파 경사심발 Fan Cut Parallel Center Cut Cylinder Cut 평행심발 Controlled Smooth Blasting Burn Cut 제어발파 Pre splitting
Tunnel Excavation Drilling: Accurate drilling leads to accurate excavation, Should deliver correct blasting power to correct direction, Too much blasting requires additional supports, Laser point survey Excavation Method Blasting Method: V-Cut Most common method, easy set up Big muck size scattering less Noisy and large vibration Ideal to point to the center line to maximize blasting Good for large sections, but difficult for small sections Blasting Method: Burn/Cylinder Cut Drill burn hole ( 무장약공 ) at the center Burn cut (<75mm) < Cylinder cut (>200mm) Applicable to any size of the cross section Small vibration (accurate blasting, good for urban areas) Small muck scattering further, Noisy due to burn hole Long drilling time, require accurate drilling skills and equipment 2 1 3
Tunnel Excavation Excavation Method Blasting Method: Smooth Blasting ( 제어발파 ) Difficult to expect and control blasting with common approaches Possible cracks and overbreak( 여굴 ) Controlled blasting: very difficult, Accurate design of explosive amount and drilling intervals Smooth walls Min. fracture Min. overbreak Less support required Better safety Blast damage Overbreak Contour holes act as a cushion to protect extra blasting by air voids and make smooth surface blasting by gas pressure ( 천공경보다작은지름의폭약사용 ) Pre splitting: blasting contour surface first then going to remaining parts
Tunnel Excavation Overbreak Increase project cost (normally 15-20%) due to additional explosive, muck, shotcrete and rock bolt amounts, Impossible to eliminate, target to minimize Causes Drilling equipment: Jumbo drill length 3.7m(about 26cm overbreak), 4.2m(29cm), 4.7m(39cm), Possible bending of the drill rod Drilling position and skill: Affected by working complexity Blasting method Topological condition: Changeable earth condition during excavation Allowable standards: Arch section: 15-20cm, Wall section: 10-15cm
Tunnel Excavation Mucking Take 1/4 1/3 of total project duration Mucking volume = Excavation volume x (1+overbreak %) x changing factor Original Earth Transportation Volume Unit Weight (kn/m 3 ) Volume Unit Weight (kn/m 3 ) Normal Rock 1 22 28 1.4 1.8 14 20 Soft Rock 1 20 25 1.3 1.7 13 19 Soil 1 15 22 1.2 1.5 12 18 Grade 12% or less for dump truck traveling Rail type transportation for small cross sections
Tunnel Support Shotcrete Shotcrete Mixing Portland cement, 0.1mm or less fine aggregates, 10mm or less clean and round coarse aggregates, 10MPa compressed strength for 1 day (21MPa for 28 days), 5 10% accelerating agent Most important support (first) by spraying mortar or concrete Fast gain of strength, applicable to any cross section Requirement, (1) bearing capacity, (2) adhesiveness and durability, (3) high watertightness, (4) less rebound and dust, (5) waterproof and drainage Compressed air for delivery Cement + Agg. Water Nozzle Compressed air + Accelerating Agent Screw Dry mix Process Shotcrete quality depending on worker skills Small size project Long distance delivery (200m) Poor working condition: large dust and scattering Large rebound (30 50%) Small and maintainable equipment Shotcrete Wet mix Process Good shotcrete quality control Large size project Shorter delivery (80m) Better working condition Less rebound (10 20%) Large equipment, difficult maintenance ( 막힘 )
Tunnel Support Shotcrete 두께 단면크기 Normal/Hard Rock Soft Rock Weathered Rock Soil 30 m 2 or less 5cm 5 10cm 5 10cm 10 15cm 30 40m 2 5 10 10 15 15 20 about 20cm 40 80m 2 5 10 10 15 15 20 20 25cm 80 120m 2 5 10 10 20 15 20 about 25cm For very stable and hardened earth, possible less than 5cm If too weak, avoid too thick shotcreting and consider to use rebar or steel fiber with shotcreting Gushout water PVC pipe Excavation Finishing( 먼지, 부석등에의한타설후박리방지 ) 즉시, Shotcreting 1m from the surface, vertical to surface, wall to arch( 탈락한숏크리트는바닥면에쌓임 ), 10cm or less at one time and repeat ( 박리방지 ) Shotcreting 용수에의한숏크리트탈락방지 배수파이프설치후타설소량의용수 : 마른상태의숏크리트를용수와혼합시킨후타설
Tunnel Support Steel Fiber Reinforced Shotcrete (SFRS, 섬유보강숏크리트 ) Steel fiber, glass fiber, plastic fiber Steel fiber: 700MPa or over tensile strength, 0.3-0.6mm diameter, 30-40mm length Early reaching good bearing strength for loading, bending stress, and impact Less void in shotcrete, used for wet-mix only Wire Mesh + Shotcrete ( 철망을설치하고숏크리트타설 ) Difficult to install if large overbreak Less adhesiveness and layer separation with vibration to the mesh during shotcreting Decreased supporting effect considering the time for mesh installation SFRS ( 숏크리트의인장강도를보완하기위해강섬유를혼입 ) Uniform thick placement of shotcrete Good bearing capacity with reduced thickness of shotcrete Prompt placement and support right after excavation Simple operation and good quality
Tunnel Support Rock Bolt Function Effect Concept 봉합또는매달음작용 보형성작용 내압작용 아치형성작용 지반보강작용 이완된암괴를원지반에고정하여낙하를방지하며균열이나절리가발단된지반에서숏크리트와병용하면작은균열에도효과적 층상으로절리가발달된지반에서록볼트로절리면사이를조여서전단력을전달하여합성보로거동 록볼트의인장력에의하여터널벽면내압이발생하여터널주변지반을잡아줌 시스템록볼트에의해내하능력이커진굴착면주변의지반이내공측으로일정하게변형하여내하력이큰아치가형성 록볼트를타설하면지반의전단저항력이증대하여지반내하력과항복후의잔류강도가증가 Head bolting ( 선단정착형 ), Whole surface bolting ( 전면접착식 ), Combination ( 혼합식 ), Friction bolt ( 마찰형 )
Tunnel Support Rock Bolt Type 선단정착형 ( 선단을암반에정착 ) By equipment: wedge type, expansion type By capsule: resin type Good for ground sealing, normal/soft rocks 전면접착형 ( 전체길이를암반에정착 ) Fix total rock bolt to the earth with filler( 충진재 ) Soft/weathered rocks 혼합형 Head bolting + Cement grouting 마찰형 Expansion Whole surface bolting starts bearing once the filler is hardened, the friction bolt immediately supports once placement ( 수압으로볼트를팽창 ) Resin Type Wedge
Tunnel Support Rock Bolt
Tunnel Support Rock Bolt Instant installation when earth pressure is big If not (for hardened earth), install every 2 3 cycles Resin Type Drilling: (1) if the hole is too small, difficult to insert bolt and adhesive; if the hole is too big, difficult to reach enough settlement; (2) Drill little bit deeper than the rock bolt length for expansion type, shorter for wedge and resin types ( 지압판부착을위해서 ) Earth Type Function Installation Concept 연암 중경암 봉합효과 암괴를봉합하여붕락방지 아치부에배치 풍화암 연암 내압및아치형성 시스템록볼트로내압및보형성효과를기대, 터널아치부와측벽부에배치, 팽창성지반은인버트에도배치 토사 전단저항 연약한지반의터널측벽부에발생하는 전단파괴를방지하도록배치, 아치 천단부를제외한아치및측벽부에배치
Tunnel Support Rock Bolt Anchor Plate ( 지압판 ) Unification of rock bolt and shotcrete Normally 150x150mm with 6mm thickness (9mm for expandable earth) If vertical rock bolting is difficult, use a circular anchor plate Self Drilling Rock Bolt ( 자천공록볼트 ) When difficult to maintain holes after drilling especially for very weak earth, drill by 2 5m rock bolt with bit and do grouting
Tunnel Support Steel Support Directly support earth until the shotcrete reach the required bearing capacity, distribute loads to shotcrete, and shape the tunnel cross section H type steel support (H 형강지보재 ) Good strength and bearing capacity usually used for weathered or soil earth Heavy Possible voids between earth surface and the steel support where shotcrete is difficult to reach If the thickness of shotcrete is thin structural integrity b/w them becomes poor Lattice Girder ( 격자지보재 ) Triangular or rectangular steel structure Lighter than other supports easy to deliver and install Forepoling can be placed through lattice spaces high construction efficiency Less strength than H type Very good adhesiveness with shotcrete, less rebound of shotcrete, good quality control For weak earth, install wood, concrete, or steel baseplate and supporting concrete
Additional Supports 굴착보조공법 Thin earth surface and weakened earth Preventing any possible deflection that affects adjacent structures The earth having a large amount of gushout water Purpose Method Earth Normal Soft Soil 지반강화및구조적보강 천단안정 Pipe Roof ( 파이프루프 ) Δ Δ Sloping Rock Bolt ( 경사록볼트 ) Δ Forepoling ( 훠폴링 ) Δ Δ Reinforced Protective Umbrella ( 대구경강관다단그라우팅 ) Δ Ο Liquid Injection ( 약액주입 ) Ο 막장면 / 바닥면안정 Tunnel Face Shotcrete ( 막장면숏크리트 ) Δ Ο Tunnel Face Rock Bolt ( 막장면록볼트 ) Δ Δ Ring Cut ( 코어핵 ) Δ Δ Temporary Invert ( 가인버트 ) Δ Δ 용수대책 지수 / 배수 Liquid Injection ( 약액주입 ) Δ Ο Ο De watering ( 물빼기공 ) Δ Ο Ο Well Point ( 웰포인트 ) Deep Well ( 딥웰 ) Ο Ο
Additional Supports Top Surface Stabilization Forepoling( 굴착전터널천단부에종방향으로철근이나강관을설치 ) Strengthen/tighten top and top front surface and prevent spalling and falling D25 supporting rebar or 30 40mm steel pipe in 2 3 times length of excavated earth length Every 0.3 0.8m ( 횡방향 ), every 막장 ( 종방향 ) From the top point 30 60 degree to left and right sides To prevent overbreak drill less than 15 degree and mortar grouting after placement Pipe Roof When the tunnel passes under the adjacent structure, support weak top earth Expensive and require spaces for working platform and various installation equipment 6 15m length, 3 4mm thickness, 50 300mm diameter, every 2 2.5 times than diameter Horizontally (less than 5 degree) install
Additional Supports Top Surface Stabilization R.P.U.M (Reinforced Protective Umbrella Method, 대구경강관다단그라우팅 ) Place long umbrella shape tubes (steel pipe or Fiber Reinforced Pipe) to the tunnel front areas and insert grouting Soil, weathered, or broken earth, minehead, and thin earth Tunnel Face Stabilization Ring Cut Leave 2 3m core at the tunnel face to resist to pressure Tunnel Face Shotcrete or Rock Bolting For protecting possible collapse within one cycle of operation
Concrete Lining Function Structurally stable: Should bear long-time earth pressure without cracks, deformation and collapse and enough durable to resist to settlement Less leakage and good watertightness Maintain convenience for ventilation, lightening, and other O&M More unstable earth and earth pressure more circular shape Invert When uneven earth pressure is expected or for poor earth conditions, install inverts immediately as connection to side walls for better bearing capacity Less deflection of tunnel structure
Concrete Lining
Concrete Lining
Concrete Lining Place after all tunnel structure is settled without further deformation or settlement and waterproofing/drainage is finished. Portland cement with AE agent and high-range water reducing agent 12-18cm slump, 21MPa designed strength, 20-40cm thickness for less bending moment Forms ( 조립식, 이동식 ) Normally use a whole section movable form (nontelescopic form), 9-12m form length
Concrete Lining Lining Cracking Reduce strength and watertightness that cause leakage, icecle, or freezing Special monitoring for areas having a large amount of gushout waters and short tunnels/ 갱구부 where can be easily affected by outside weather Crack more due to drying and shrinkage than increased tensioning Cause (1) Concrete Materials Cement abnormal expansion/freezing Concrete settlement/bleeding Cement hydration heat Aggregates quality Concrete stiffening/drying shrinkage Cause (2) Loading Actual loading over designed loading Earthquake Lack of cross sections and rebar Earth differential settlement Cause (2) Construction Process Too long concrete mixing W/C ratio changes during pumping Wrong concrete placement Too fast curing and lack of compaction Moved rebar positions Non tight connection b/w parts Deformation of forms and supports Leakage Form earth removal Vibration and loading before stiffening Rapid drying during curing Fiber Reinforced Concrete Wet Curing with Sprinkler Use of Spacer
Open Cut Tunnel ( 개착터널 ) 갱구부및터널중간계곡부의개착부분, 터널과터널사이의길이가짧을경우에터널로연장시키고자할때 Excavation Tunnel Construction Refilling Open Cut through Precase Concrete Assembly Foundation + Prefabrication ( 반아치형세그먼트 ) simultaneous construction Fast Good quality, light, durable less cracking, good watertightness and efficient maintenance Thin thickness of the segment economical, easy transportation and construction 돌출형갱문의개착터널 면벽형갱문의개착터널 계곡통과시개착터널
Immersed Tunnel ( 침매터널 )
Immersed Tunnel Transport prefabricated immersed tunnel segments and sink them by filling waters into the ballast tank in the segments Joint is the most important part to determine life and performance of the tunnel, allow very limited movement Rectangle: better space use, thicker cross section due to larger bending moment Immersion Joint: 침설조인트는침설된선행함체와연결되는부분의접합을위한조인트로서고무재질로제작되어침매함체의양단에설치. 풀링잭시스템으로두함체를 1 차접합시키고두함체연결부의가격벽사이에있는물을배제시켜서연결부를대기압상태로만들면연결부와침설함체양단의압력차에의해연결부에기설치된고무친설조인트가 2 차수압으로접합 Segment Joint: connect segments with rubber waterstops
Immersed Tunnel Gravel bed Sink tunnel Locking fill to prevent movement Backfill and rock protection Internal finish DCM/SCP 등기초보강중요 거가대교 : Busan Gerjae Do 8.2km, 48m depth Immersed tunnel
TBM (Tunnel Boring Machine) Manual Big Tunneling Machinery Better safety, Reduce blasting pollution, Less public complaint
Open TBM Cutter Head: 커터의압축력과회전력에의해암석을압쇄시켜굴착하고버력을설치된벨트컨베이어에적재하여후방으로배출시키며내부켈리의작동으로전진 Cutter Head Jacket: 커터헤드를둘러싸고있어서터널벽면으로부터떨어지는낙반을방지하며클램핑및리셋팅시에본체전방지지대의역할과굴진중에커터헤드를지지하여본체의진동을감소 Inner Kelly: 유압작동으로커터헤드를회전 / 전진시킴 ( 커터헤드드라이브 ) Outer Kelly: 내부켈리를감싸며굴착운행시본체를지지하는클램핑패드장치가있어터널벽면에압착지지하여 TBM 이전진하면서굴착 Trailer: 유압시스템, 버력처리시설로구성
Open TBM Cutting style Rotating button cutter, weathered ground Crushing style Rotating disk cutter, harder ground than cutting style 1. 클렘핑패드를터널벽면에압착 2. 기계지지대를위로오므림 3. 커터헤드가작동시작 1. 1 stroke 굴진완료 2. 내부켈리의전진상태 1. 기계지지대를지상으로내림 2. 클렘핑패드를터널벽면에서풀음 1. 외부켈리를 1 stroke 전진 2. 기계지지대로터널의굴진방향을조정
Open TBM Manufacturing Site Width = Main TBM width + crane operation width Length = Main TBM length + trailer length Pilot Tunnel ( 발진터널 ) For the first placement not using clamping pad, excavate or blast access having 30cm extra width Loss time이적어효율적, 연속적버력처리가능고가초기투자비, 디젤기관차환기용량증가연속적버력처리가능, 가장효율적고가초기투자비, 벨트의재사용곤란, 인원및자재수송에별도시설이필요 초기투자비저렴환시설비용량증가, 연속적인버력처리가불가능, 인원대피및덤프트럭운행을위한시설이필요 Concrete Lining Needle beam form: 9 12m, 유압잭에의해서이동 Telescopic full round form: 30 36m, 작업대차를사용하여이동및조립
Shield TBM
Shield TBM Hood Cutter Head Hood Girder Tail Girder Full Face Cutting Type (Flat Dome) Better compaction of tunnel face Spoke Type (Flat) Less torque, Easy mucking 외부토압지지, 후드와테일을연결, 본체는테일부세그먼트의반력으로부터거더부잭의추진력을받아서추진 Tail 스킨플레이트 : 쉴드본체는굴착, 추진장치를보호하기위하여외곽에작용하는토압에견디도록스킨플레이트로둘러싸고링거더등으로보강 테일씰 : 스킨플레이트내측과세그먼트외측의사이로뒤채움재, 지하수, 이토사등이유입되지않도록고무등의재료로설치 중절장치 : 급곡선시공에서는 2단, 3단의중절장치를사용하여곡선부여굴량을적게하고중절에의해서구부리기쉽도록함
Shield TBM Take off ( 발진 ) Reaction system to push enough and protect adjacent environment and structures Entrance packing to prevent injection of underground water and soils Stabilization of ground for taking off Segment Placement Erector
Shield TBM Segment Placement Curved Bolt Structurally effective Bolt Box Corrosion/Loose, Big possible leakage Sloped Bolt Not fully connected, Weak to twisting, Possible leakage Connection Bar No corrosion, Possible leakage with time, Impossible to take apart Backfilling( 뒤채움주입 ): 세그먼트와굴착한지반사이에서필연적으로발생하는공극을채움
Shield TBM
Shield TBM