Face

Support in
Soft-Ground TBMs

Lars Babendererde
Babendererde Engineers GmbH
Outline

§ Face support models

§ Advise for practical use

§ General strategies after face support loss

§ Things to do and things not to do after a face collapse

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Why is ground support in soft ground tunneling a must?

§ Minimize settlements, thus

preventing sinkholes.
§ A stabilized face allows for
reliable TBM advance.
§ Basis for proper bedding of the
tunnel.
§ Allows safe cutting head
maintenance with pressurized
air interventions.

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Which loads are driving the pressure?

§ Water pressure
§ Earth pressure
§ Loads from surface structures
§ Loads from traffic

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To small face pressure leads to sinkholes

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Filter Cake for Support Pressure Application

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Face Support Application EPB-TBM

For reliable face support, the

conditioning agent has to be
injected through multiple ports
already into the tool gap for
immediate ground treatment.

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Calculation of face support – historic

Section Longitudinal Cut

Early research by Forchheimer (1883) using sand box models

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Calculation of face support – historic

But how to calculate the face pressure?

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Calculation of face support – historic

But how to calculate the face pressure?

Possible solution: back to the basics Þ at-rest earth pressure!

𝜎",$ = 𝐾$ ∗ 𝛾 ∗ 𝑑
But much higher than
required for face stability

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Calculation of face support – historic

Closing in on reality from the safe side Þ 2-dimensional failure case

“Retaining wall” failure

type with TBM

𝜎",* = 𝐾* ∗ 𝛾 ∗ 𝑑

Still higher than required

for face stability

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Calculation of face support – historic

Closing in on reality from the safe side Þ horizontal arching

3-D sliding bodies with full

earth load on top

Þ Pressure still higher than

required, especially at
increasing depths

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Calculation of face support – historic

Closing in on reality from the safe side Þ vertical arching above sliding wedge

Many different models

published, e.g.
§ Horn (1961)
§ Mohkam (1991)
§ Anagnostou & Kovári (1992)
§ Jancsecz (1994)

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Calculation of face support

Advise for practical use:

§ Most models are lower limit equilibrium
models
§ Reduction of earth pressure below the
at-rest state (K0) requires soil
movement/settlement
§ But: no model does actually require to
make use of the lower pressure limit!

www.facesupport.org

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Pressure has to be transferred onto the face

Slurry TBM:
§ Calculate rheological parameters

d10 • g ´
tF ³
tan j

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Pressure has to be transferred onto the face

Slurry TBM:
§ Calculate rheological
parameters
§ Control the Key
Performance Parameters

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Pressure has to be transferred onto the face

EPB TBM:
§ Control the viscosity

dry soil + water + additives (source BASF)

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Filter Cake for Support Pressure Application

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Pressure has to be transferred onto the face

Time Dependency:
During advance the
boundary lines of the
membrane are well defined
and the pressure difference
is high.

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Pressure has to be transferred onto the face

Time Dependency:
During stoppage the
membrane expands into the
ground and the pressure
difference at the initial
depth decreases.

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Pressure has to be transferred onto the face

Time Dependency:
In the worst case the
membrane expands beyond
the soil wedge, thus
destabilising the tunnel
face.

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Pressure has to be transferred onto the face

Time Dependency:
The same applies to EPB-
TBMs, even faster time as
air penetrates into soil 70
times faster than water
would do.

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Pressure has to be transferred onto the face

Without control:

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What to do after loss of face support?

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Partial collapse, but TBM operational

Common reflex Þ Stop, analysis, debate, concrete,…

Risk Þ secondary collapse leads to cutter head blockage.

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Partial collapse, but TBM operational

Better solution: in case of no direct danger…

Þ Move cutter head out of disturbed zone asap
Þ use tail void grout system for ground stabilisation

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Partial collapse, but TBM not operational

Find a way to stabilize the face and apply face pressure

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Regaining face support – do not …

… try to use Styrofoam

It is lighter than any suspension and thus will accumulate in the top of the excavation
chamber.

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Regaining face support – do not …

… try to use saw dust or straw

It is lighter than any suspension and thus will accumulate in the top of the excavation
chamber.

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Regaining face support – do not …

… try to use Polyurethane foam

PU foam tends to stick to any surface, as well on the cutterhead and is difficult to remove.

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Regaining face support – do … [Stage 1]

… use large-size polymers

§ The large-size polymers have comparable density to bentonite suspension.

§ The polymers clog only on soil.

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Regaining face support – do … [Stage 1]

… use large-size polymers

ü Cheap
ü Easy and quick to apply
ü Sizes up to 20 mm available
ü But only small voids in the face are acceptable for this method

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Regaining face support – do … [Stage 2]

… use sprayable membrane

§ Membrane is not drying out like bentonite

§ Direct pressure transmission onto face
§ Not flammable

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Regaining face support – do … [Stage 2]

… use sprayable membrane

§ Applicable on soil, rock, steel

§ High tensile strength
§ Airtight

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Regaining face support – do … [Stage 2]

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Regaining face support – do … [Stage 3]

… use artificial soil

§ Blow out
§ Cutterhead needed welding
§ 3 months standstill

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Regaining face support – do … [Stage 3]

… use artificial soil

§ Mixing and testing on site

§ Ready to use after 3 days

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Regaining face support – do … [Stage 3]

… use artificial soil

§ Safe working condition, no air loss

§ Exchanged tools and restart tunnelling after 3 weeks

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Summary

§ Understanding of the face support model used and it’s

limitations is essential.

§ Tolerable face support pressure range should be calculated, not

just the lower limit.

§ Face support failure might require swift action rather than a full
stop.

§ There are proven methods for regaining face control during

intervention.

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Thank you for your attention

contact@tunnelsoft.com

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