Applications of NTNU/SINTEF Drillability Indices in Hard Rock Tunneling

Drillability indices, i.e., the Drilling Rate Index? (DRI), Bit Wear Index? (BWI), Cutter Life Index? (CLI), and Vickers Hardness Number Rock (VHNR), are indirect measures of rock drillability. These indices are recognized as providing practical characterization of rock properties used in the Norwegian University of Science and Technology (NTNU) time and cost prediction models available for hard rock tunneling and surface excavation. The tests form the foundation of various hard rock equipment capacity and performance prediction methods. In this paper, application of the tests for tunnel boring machine (TBM) and drill and blast (D&B) tunneling is investigated and the impact of the indices on excavation time and costs is presented.     

A Completely 3D Model for the Simulation of Mechanized Tunnel Excavation

For long deep tunnels as currently under construction through the Alps, mechanized excavation using tunnel boring machines (TBMs) contributes significantly to savings in construction time and costs. Questions are, however, posed due to the severe ground conditions which are in cases anticipated or encountered along the main tunnel alignment. A major geological hazard is the squeezing of weak rocks, but also brittle failure can represent a significant problem. For the design of mechanized tunnelling in such conditions, the complex interaction between the rock mass, the tunnel machine, its system components, and the tunnel support need to be analysed in detail and this can be carried out by three-dimensional (3D) models including all these components. However, the state-of-the-art shows that very few fully 3D models for mechanical deep tunnel excavation in rock have been developed so far. A completely three-dimensional simulator of mechanised tunnel excavation is presented in this paper. The TBM of reference is a technologically advanced double shield TBM designed to cope with both conditions. Design analyses with reference to spalling hazard along the Brenner and squeezing along the Lyon–Turin Base Tunnel are discussed.     

Experimental and Numerical Studies on Rock Breaking with TBM Tools under High Stress Confinement

Summary The understanding of rock breaking and chipping due to the TBM cutter disks mechanism in deep tunnels is considered in this paper. The interest stems from the use of TBMs for the excavation of long Trans-Alpine tunnels. Some tests that simulate the disk cutter action at the tunnel face by means of an indenter, acting on a rock specimen are proposed. The rock specimen is confined through a flat-jack and a confinement-free area on one side of the specimen simulates the formation of a groove near the indenter, like it occurs in TBM excavation conditions. Results show a limited influence of the confinement stress versus the thrust increment required for breaking the rock between the indenter and the free side of the specimen. Numerical modelling of the cutter disk action on confined material has also been carried out in order to investigate further aspects of the fracture initiation. Also in this case the importance of the relative position between disk cutter and groove is pointed out.     

Estimation of the performance of the tunnel boring machine (TBM) using uniaxial compressive strength and rock mass rating classification (RMR)–A case study from the Deccan traps,India

The competency of any TBM in any geological condition is determined by a rock or rock mass breakage process. A 12.24 km long tunnel between Maroshi and Ruparel College was excavated by Brihanmumbai municipal corporation (BMC) to improve water supply system of greater Mumbai, India, using open-type hard rock tunnel boring machines (TBMs). In this paper an attempt has been made to establish the relationship between rock mass characteristics i.e. RMR and UCS of the Deccan trap rocks and TBMs performance characteristics for 5.83 km long Maroshi–Vakola tunnel section of the Maroshi–Ruparel college tunnel project. To analyze the effect of variable rock mass conditions on the TBM performance, the operating parameters i.e. thrust force, torque and RPM of the machine, were recorded and intact rock strength was determined. The effect of rock mass properties on machine penetration rate (PR) and the relation with other operational parameters were analyzed. The rock strength affects the rock behaviour under compression. When the rolling cutters indent the rock, the stress exerted must be higher than the rock strength i.e.; the rock strength is directly relevant to the performance of TBM. Studies show that the penetration rate decreases with increase in uniaxial compressive strength (UCS). The comparison of measured penetration rate with empirical model developed by Graham, in which, the penetration rate is computed using UCS and average thrust per cutter, showed good agreement with coefficient of determination (R²), i.e. 0.97. The study shows that the TBM performance was maximum in rock mass rating (RMR) range from 40 to 75, while slower penetration was recorded both in very poor and very good rock masses.     

Rock burst and slabbing failure and its influence on TBM excavation at headrace tunnels in Jinping II hydropower station

Two headrace tunnels and the drainage tunnel were excavated by tunnel boring machines (TBMs) in Jinping II Hydropower Station. During TBM excavation, two types of slabbing failure were encountered in these deep buried marble tunnels. One is rock bursting and the other is non-violent slabbing. In order to study the rock burst and slabbing failure, a unique true triaxial rock burst test was carried out to simulate the rock burst process with different in situ stresses. Four rock samples in different marble layers were obtained in the site, and then four experiments are conducted under the same stressed conditions as the in situ field. The rock burst process and slabbing failure phenomena of the four experiments are in good accordance with the observations of corresponding excavation site. The failure modes of slabbing and rock burst in different rock groups can be predicted based on the experiments. The influence of the slabbing and rock burst failure on TBM excavation is analyzed in depth. Non-violent slabbing is beneficial to the rock breakage process. Rock burst with violent slabbing process greatly affects the tunnel support, cutter and cutterhead damage, gripper movement and force and so on.     

Some Attempts for Estimating Rock Strength and Rock Mass Classification from Cutting Force and Investigation of Optimum Operation of Tunnel Boring Machines

Summary. Tunnel face and wall collapse are common during excavations performed by tunnel boring machines (TBMs) due to the difficulty of correctly identifying the properties of the excavated rock. This identification, however, can be simplified by using the cutting force to estimate rock strength, a method that has already proved quite successful in Japanese tunnel excavations. This paper summarizes knowledge relating to the cutting force obtained through tunnel excavation experience, and the relationship between rock strength and TBM operation is discussed. Although TBM operators rely on intuition to set the cutter head speed appropriately, this decision process represents a logical method of operation that takes advantage of the variable speed capability of the cutter head. Selection of appropriate support methods for the excavated face is also a critical issue in tunnel excavation. This selection process is based on the condition of the rock, which is difficult to determine quickly and accurately during tunnel excavation. The present paper uses the excavation of two tunnels to demonstrate that it is possible to assign rock mass classifications accurately based on rock strength when boring a uniform rock type. It is also shown that the rock mass can be classified from the rock strength normalized by the uniaxial compressive strength when boring through mixed rock types.     

TBM Performance Analysis in Pyroclastic Rocks: A Case History of Karaj Water Conveyance Tunnel

Karaj Water Conveyance Tunnel (KWCT) is 30-km long and has been designed for transferring 16 m³/s of water from Amir-Kabir dam to northwest of Tehran. Lot No. 1 of this long tunnel, with a length of 16 km, is under construction with a double shield TBM and currently about 8.7 km of the tunnel has been excavated/lined. This paper will offer an overview of the project, concentrating on the TBM operation and will review the results of field performance of the machine. In addition to analysis of the available data including geological and geotechnical information and machine operational parameters, actual penetration and advance rates will be compared to the estimated machine performance using prediction models, such as CSM, NTNU and Q_TBM. Also, results of analysis to correlate TBM performance parameters to rock mass characteristics will be discussed. This involves statistical analysis of the available data to develop new empirical methods. The preliminary results of this study revealed that the available prediction models need some corrections or modifications to produce a more accurate prediction in geological conditions of this particular project.     

Theoretical and Experimental Results from Laboratory Tests by ILCM

The intermediate linear cutting machine (ILCM) is a machine designed to work on an intermediate scale between the full- and the small-scale. The reduced scale involves several advantages compared to full-scale tests, especially in terms of sample supplying and transportation. On the other hand, it has an impact on the testing conditions, resulting in a limitation of the cutting penetration and spacing during the test, as well as in a smaller disc cutter. This affects most of the results, which cannot be directly used for the on-site machine performance prediction. However, some experimental results provided in the literature show that the optimal spacing/penetration ratio is not significantly affected by the changes involved. On this basis, the results obtained from ILCM tests should provide reliable information about the optimal cutting conditions of a tunnel boring machine in massive rock mass. The work performed included the development of some improvements of the testing rig, as well as a modified ILCM testing procedure, according to the one typically used in standard LCM tests. The results provide information about the attitude of the tested lithotypes to mechanical excavation by means of disc tools, including the optimal cutting conditions. Additional work was developed in terms of detailed characterisation of the rock samples involved and assessment of the size distribution of the debris produced during the ILCM tests. Nevertheless, further tests are necessary, in order to assess the consistency of the experimental procedure employed and to investigate the scale effect.

     

Advance numerical simulation of tunneling by using a double shield TBM

Double shield TBMs are amongst the most technically sophisticated excavation machines in use by tunneling industry. However, using the shielded machine limits access to the walls for observation of ground conditions and presence of shield makes the machine susceptible to entrapment or seizure in weak rocks under high stresses which results in high convergence. To realistically evaluate the possibility of machine seizure in such grounds, the interaction between the rock mass and shields, lining and backfilling need to be understood. This study explains the application of numerical analysis for 3D simulation of mechanized tunneling by using a double shield TBM. For this purpose, a comprehensive numerical simulation is developed to systematically evaluate the potential of excessive ground convergence. Simulation results at five reference points on the tunnel circumference along the tunnel have been examined. The results are including longitudinal displacement profile (LDP) as well as contact force profiles (LFP) on both front and rear shields, frictional forces and required thrust to move the machine, stress history of ground, and estimated loading of the segments. The results also proved that numerical analyses can successfully be used for prediction of loads on the shield during excavation to assess risks of machine entrapment.     

Estimation of the Specific Energy of TBM Using the Strain Energy of Rock Mass,Case Study: Amir-Kabir Water Transferring Tunnel of Iran

The specific energy (SE) is the most important parameter to estimate the energy consumption in tunnel boring machines (TBMs). It is defined as the amount of required energy to excavate a unit volume of rock mass which used to predict the performance of TBMs. Several models are used to estimate the SE based on different parameters such as the rock mass properties, disc cutter dimensions and cutting geometry. The aim of this work is to propose new relations between the SE and the strain energy of rock mass (W) using the geological mappings of rock mass and TBM operational parameters from Amir-Kabir Water Transferring Tunnel of Iran. W is an appropriate criterion to estimate SE because it is a function of different parameters such as rock mass behavior, pre and post failure properties and peak and residual strains. In this study, to increase the correlation coefficient of relation between the mentioned parameters, the rock mass is classified in two methods, in the first method according to the geological strength index (GSI) all data is classified in three classes such as weak, fair and good and in the second method using the drop to deformation modulus ratio (η) the classification of data is performed in three classes such as η < 0.05, 0.05 ≤ η < 10 and η ≥ 10. The results show that there are direct relations between both parameters. It is suggested to estimate SE in all rock mass classes using the proposed relations based on GSI classification.     

A Top Pilot Tunnel Preconditioning Method for the Prevention of Extremely Intense Rockbursts in Deep Tunnels Excavated by TBMs

The headrace tunnels at the Jinping II Hydropower Station cross the Jinping Mountain with a maximum overburden depth of 2,525 m, where 80% of the strata along the tunnels consist of marble. A number of extremely intense rockbursts occurred during the excavation of the auxiliary tunnels and the drainage tunnel. In particular, a tunnel boring machine (TBM) was destroyed by an extremely intense rockburst in a 7.2-m-diameter drainage tunnel. Two of the four subsequent 12.4-m-diameter headrace tunnels will be excavated with larger size TBMs, where a high risk of extremely intense rockbursts exists. Herein, a top pilot tunnel preconditioning method is proposed to minimize this risk, in which a drilling and blasting method is first recommended for the top pilot tunnel excavation and support, and then the TBM excavation of the main tunnel is conducted. In order to evaluate the mechanical effectiveness of this method, numerical simulation analyses using the failure approaching index, energy release rate, and excess shear stress indices are carried out. Its construction feasibility is discussed as well. Moreover, a microseismic monitoring technique is used in the experimental tunnel section for the real-time monitoring of the microseismic activities of the rock mass in TBM excavation and for assessing the effect of the top pilot tunnel excavation in reducing the risk of rockbursts. This method is applied to two tunnel sections prone to extremely intense rockbursts and leads to a reduction in the risk of rockbursts in TBM excavation.     

Mechanical response of surrounding rock of tunnels constructed with the TBM and drill-blasting method

There are two kinds of excavation methods in underground engineering: the tunnel boring machine (TBM) and the drill-blasting method. A large number of studies have shown that the deformation and failure, the degree of disturbance, the stability and the reinforcement measures of surrounding rock using the TBM and drill-blasting method vary from each other. To accurately master these macroscopic damages, it is necessary to focus on the investigation of the micro-mechanical responses of the surrounding rock. Scanning electron microscopy tests, acoustic emission tests and tunnel acoustic detection tests were carried out to analyze the mechanical response of surrounding rock of tunnels, which were excavated in marble by, respectively, the TBM and the drill-blasting method. The tests results showed that most of the rock fractures cut by TBM is wipe along the crystal, and the failure mechanism is mainly cutting, while most of the rock fractures induced by the TBM coincide with crystal planes, its mechanism is mainly tensile. The stress–strain curves of rocks cut by the TBM method are rather flat around the peak strength, which means a strong resistance to deformation around the peak load. The response of AE for the rock cut by the TBM method appears after larger strains than the response of the rock constructed by the drill-blasting method. This suggests that the resistance to damage is higher under TBM excavation conditions. The relaxation depths of the tunnel excavated by the drill-blasting method are larger than the tunnel excavated by the TBM method. The research can provide more insight into tunnel failure mechanisms and provide a framework for reinforcement measures.     

TBM滚刀破岩过程影响因素数值模拟研究

全断面岩石掘进机（TBM）的破岩效率主要受刀盘设计和岩体特征的影响。采用颗粒流方法建立了岩石试件与滚刀的数值模型,对TBM滚刀破岩过程的影响因素进行了分析。研究表明,单刃滚刀交替作用下强度较低的岩石中易形成规则的张拉裂纹而生成较大岩碴;强度较高的岩石中滚刀的侧向挤压促使形成块度较小的片状岩碴;双刃滚刀作用下岩石表面受到强烈挤压后出现较大的拉应力,使岩石更易破碎,且仅在强度较高的岩石中才易形成透镜状岩碴。滚刀破岩过程中存在能耗最小的最佳间距,该最佳间距随着岩石强度的增大而减小。滚刀破岩过程中,结构面对裂纹扩展具有显著的控制性作用,并阻隔损伤向结构面下的岩石中渗透;随着结构面与滚刀侵入方向夹角的减小,结构面将引导裂纹向岩石深部扩展,而当夹角较大时,结构面则会引导裂纹横向扩展,易导致大块岩碴的形成     

灰岩隧道掘进机隧道点荷载试验评价岩石强度方法的研究与探讨

使用隧道掘进机（TBM）开挖隧道时刀盘和盾体阻碍了对岩石状态的观察,这时可使用岩渣对岩石条件进行预测和评价。从滚刀破碎掌子面产生的岩渣中选取块状岩石进行点荷载试验可以获得岩石强度,但是受过滚刀损伤作用的岩石强度值与未受损伤的岩石强度值之间的关系尚不明确。从吉林引松供水工程TBM破岩产生的岩渣中挑选块状试样进行点荷载试验,同时在产生岩渣的相应位置钻取岩芯获取点荷载强度,与单轴抗压强度进行了对比,记录了取样地点地质状态、试样的尺寸、破碎状态以及等效断裂面积。结果表明：岩渣中的岩块受到滚刀作用产生的损伤强度值有所下降,为完整取芯试样的63.25%,原岩越完整受损程度越大;灰岩点荷载强度换算岩石单轴抗压强度系数约为25.3,直接使用岩渣时建议系数约为42.1;峰值荷载与等效断裂面积成正比;尺寸过大的试块往往与岩体原有裂隙有关,强度极低,不适宜用作点荷载试验。研究结果为TBM隧道现场快速获取岩石强度参数提供了方法和依据。     

Parameter Study on Prediction Methods for TBM Penetration Rate

Penetration rate prediction of Tunnel Boring Machine (TBM) is the first step to advance prediction process of mechanized tunnelling. In this research, influence of effective parameters on TBM penetration rate is investigated by sensitivity analysis of three main TBM performance prediction methods; Norwegian University of Science and Technology (NTNU), rock mass index (RMi) and Q_TBM. Based on these analyses, it is shown that applied thrust per disc and joint spacing in NTNU and RMi models have more influence on penetration rate. In Q_TBM model, Q value, applied thrust per disc and induced biaxial stress are more effective.     

全断面隧道掘进机分类及其应用范围(英文)

目前,隧道掘进机的机械化及自动化水平得到了很大提高,隧道掘进机可以开挖不同的地质条件下各种形状的隧道。隧道掘进机的类型也越来越多,根据隧道工程场地所处的水文地质与工程地质条件,工程的使用特性及环境的限制,不同类型的隧道掘进机的工作机理需要进一步的理解并依此进行分类,以便选择合适的隧道掘进机。本文介绍了各种类型的全断面隧道掘进机的运行机理,并根据最终开挖隧道断面,掌子面的支护类型及岩土体的破碎机理对全断面隧道掘进机进行分类。本文也总结了各类型的隧道掘进机的应用范围。使用者可根据地质条件及特殊需要对隧道掘进机进行初步的选型。     

南水北调西线TBM掘进下隧洞围岩损伤研究

为研究隧洞掘进机（tunnel boring machine,TBM）掘进下隧洞围岩的损伤特征,选取南水北调西线工程为背景工程,针对隧洞围岩TBM掘进后的损伤进行了系统的研究与分析。根据板岩在室内试验中表现出来的脆性和屈服后强度特性,提出了以黏聚力弱化-摩擦角强化（cohesion weakening and frictional strengthening,CWFS）脆性模型为基础考虑岩体屈服后损伤的本构模型,通过VC++编译dll动态链接库,并将其植入FLAC3D程序中。应用神经网络和遗传方法等优化算法对本构模型中的参数进行了反演分析,并以室内三轴压缩试验为依据,对该本构模型进行了验证。结果表明,提出的考虑损伤的CWFS模型可以较好地反映板岩的弹性特征、屈服后的强化特征、脆性破坏特征和破坏后残余强度特征。以该模型为基础,模拟了南水北调西线隧洞在TBM掘进条件下隧洞围岩的变形特性、应力发展规律及其损伤演化特征,并与基于Mohr-Coulomb本构关系的计算结果进行了对比分析。提出的考虑损伤的CWFS模型能更好地反映隧洞掘进后围岩损伤特征,即损伤沿着弱势区域发展的规律     

复合地层隧道围岩强度实时估算研究

隧道TBM开挖过程中经常会遇到复合岩层,在这种地质环境下,隧道掘进机（tunnel boring machine,简称TBM）开挖过程中的隧道围岩强度很难估计,隧道开挖掌子面和围岩容易发生坍塌。为了提高隧道掘进效率、预防事故发生,对开挖隧道围岩强度进行实时估算方面的研究很有必要。在重庆轨道九号线隧道TBM施工中,通过室内试验和现场实测数据发现,TBM推力F_N与岩石强度成正比、TBM扭矩推力比T/F_N（T为扭矩）与贯入度p^0.5成正比例关系。针对砂质泥岩、砂岩和灰岩组成的复合岩层,提出了一种利用现场实测推力F_N和扭矩T的值来快速估算开挖隧道围岩强度的方法,进一步对TBM实测数据进行线性拟合,从而得到估算公式中两个常数α₁、α₂的取值方法,并在10多个隧道实际工程中得到验证。结果表明,对于这种复合岩层地质环境,两个常数α₁、α₂的值与滚刀数量n和滚刀直径d相关。该研究成果为实时快速估算开挖隧道围岩强度提供了一种新的切实可行的思路,能提高隧道TBM施工的可靠性和安全性,具有重要的应用价值。     

Full-scale linear cutting test in Chongqing Sandstone and the comparison with field TBM excavation performance

In this study, determination of some machine parameters and performance prediction for tunnel boring machine (TBM) are conducted based on laboratory rock cutting test. Firstly, laboratory full-scale linear cutting test is carried out using 432-mm CCS (constant cross section) disc cutter in Chongqing Sandstone. Then, the input parameters for TBM cutterhead design are extracted; some TBM specifications are determined and then compared to the manufactured values. Finally, laboratory full-scale linear cutting test results are compared with the field TBM excavation performance data collected in Chongqing Yangtze River Tunnel. Results show that laboratory full-scale linear cutting test results, combined with some engineering considerations, can be used for the preliminary and rough design of TBM machine capacity. Meanwhile, combined with some modification factors, it can also well predict the field TBM excavation performance.

     

软土地层TBM开挖面支护压力计算模型及可视化

隧道掘进机（TBM）近年来在世界范围内得到了广泛应用,通常通过完全充满压力仓的泥土或泥浆来支护开挖面。但在较差的地层和水力条件下,开挖面失稳时有发生。事实上,TBM开挖面的支护压力的大小直接决定了施工安全及地表变形。基于所建立的开挖面支护压力计算模型,并考虑复合地层下土体分层带来的影响,通过计算机编程方法,建立了界面友好、使用便捷的开挖面支护压力可视化计算平台(TBM Studio);并结合阿拉斯加隧道、钱江隧道工程实例进行了不同模型结果的验证分析,给出了各模型计算结果的差异性;讨论了软土复合地层条件下,土体自稳性对开挖面稳定的影响,认为软土地层中定量确定有效支护压力和水头高度至关重要,研究为正确评价TBM开挖面稳定性提供了相应的计算模型。