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Tunnelling and Underground Space Technology 71 (2018) 1–14

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Tunnelling and Underground Space Technology


journal homepage: www.elsevier.com/locate/tust

A 3D model of coupled hydro-mechanical simulation of double shield TBM MARK


excavation

Hui Zhou , Yang Gao, Chuanqing Zhang, Fanjie Yang, Mingming Hu, Haitao Liu, Yue Jiang
a
State Key Laboratory of Geomechanics and Geotechnical Engineering, Institute of Rock and Soil Mechanics, Chinese Academy of Sciences, Wuhan 430071, China
b
University of Chinese Academy of Sciences, Beijing 100049, China

A R T I C L E I N F O A B S T R A C T

Keywords: The interactions between the surrounding rock and TBM machines under high stress and high water pressure
Hydro-mechanical coupling during the excavation of a deep tunnel by TBM need further study. To evaluate the rock mass deformation and
3D modeling pore pressure development in a realistic manner, we here established a hydro-mechanical coupled model in
Double shield TBM FLAC3D. This system can be used to monitor displacement and pore pressure at different directions around a
Deep buried tunnels
tunnel throughout the construction period, and the depth of influence of excavation on both deformation and
pore pressure will be determined. This exercise allows for evaluation of the scope of influence of tunnel con-
struction, which in turn brings insight into the areas of engineering that need the most attention.

1. Introduction backgrounds. But the water effect were barely reflected in the previous
work. The water condition of surrounding rock mass has a profound
Due to the growing number of industrial tunnel construction projects, impact on the mechanism and extent of the deformation and the sta-
especially long, deep tunnels and deeply buried main roadways in coal bility of rock mass and concrete lining.
mines, TBMs (Tunnel Boring Machines) are increasingly used because of In this paper, a three-dimensional finite element model of a division
their significant advantages in high construction efficiency, low project cost, tunnel excavated by double shield TBM (which is considered more
minimal environmental impact, favorable stability control of surrounding complicated than gripper or single shield TBM) is established to simu-
rock mass, and other qualities (Liu et al., 2016). However, the complex late the hydro-mechanical behavior of the rock mass. The coupling ef-
geological conditions can pose serious technical challenges and TBM acci- fect between stress and permeability of surrounding rock mass is taken
dents (Yang et al., 2016; Wen and Xu, 2008). It is highly necessary to de- into account by using a coupled pore fluid/stress analysis. Because
termine the mechanism underlying the deformation of the surrounding rock hydro-mechanical interaction is based on the indirect-coupled method
mass. There are some effective methods available, such as in-situ mon- in the majority of the previous works, we used direct hydro-mechanical
itoring (Kavvadas, 2005; Zhou et al., 2017), laboratory tests (Fang et al., coupling in the present research.
2016; Yang et al., 2017), and numerical simulation (Øyvind et al., 2017;
Maghous et al., 2012). Considering the cost of in-situ monitoring, the size 2. Double shield TBM technology
effect and debatable representativeness of the laboratory tests, numerical
simulation may be the optimal method. The structure and the main components of a common double shield
Toward this end, scholars have carried out studies and obtained TBM (DS-TBM) are shown in Fig. 1. The key components include the cut-
meaningful results (Zhao et al., 2012; Rohola et al., 2014; Kavvadas terhead, the front shield, the main and auxiliary thrust cylinders, the grip-
et al., 2017). By establishing numerical models, the mechanical re- pers, the gripper shield, and the tail shield. These play important roles in the
sponse of rock mass, the deformation mechanism, TBM accidents causes deformation of the surrounding rock during excavation. The real advance of
during TBM excavation were examined against different engineering DS-TBM to other TBMs is the suitability for use in both hard and soft rock


Corresponding author at: State Key Laboratory of Geomechanics and Geotechnical Engineering, Institute of Rock and Soil Mechanics, Chinese Academy of Sciences, Wuhan 430071,
China.
E-mail address: hzhou@whrsm.ac.cn (H. Zhou).

http://dx.doi.org/10.1016/j.tust.2017.07.012
Received 19 October 2016; Received in revised form 14 July 2017; Accepted 30 July 2017
Available online 10 August 2017
0886-7798/ © 2017 Elsevier Ltd. All rights reserved.
H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Fig. 1. Structure and components of a double shield TBM (www.herrenknecht.com).

Fig. 2. Sketch of DS-TBM tunnel construction process.

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Fig. 3. A simplified DS-TBM sketch.

Table 1
Main features of DS-TBM.

Description Unit Value

Cutterhead
Excavation radius m 6.3

Front shield
Outer radius m 6.28
Length m 5

Gripper shield
Shield outer radius m 6.25
Shield length m 6
Gripper length m 2
Gripper height m 10
Maximum normal Thrust MN 80
Maximum shear thrust MN 16

Tail shield
Outer radius m 6.22
Length m 4

Segment
Inner radius m 5.4
Outer radius m 6.2
Thickness m 0.8
Length (1 ring) m 1

Backfilling
Inner radius m 6.2
Outer radius m 6.3
Thickness m 0.1

Machine
Weight t 2500
Maximum main thrust MN 32
Maximum auxiliary thrust MN 32

Table 2
Loads.
• Phase I. The cutterhead and front shield are assembled and jacked
into the ground. The surrounding rock deformation is limited by the
shield, while a normal force performing on the tunnel face.
σxx σyy σzz

Item Groundwater
Phase II. The cutterhead and front shield keep advancing; the
Value −41.6 MPa −44.2 MPa −53.1 MPa 3.0 MPa gripper shield is assembled and pushed into the ground. What
should be noted is that the driving force is provided not by the
grippers but the working shaft.
and even in soil. By transferring the driving system from the grippers and
the main thrust cylinders to the auxiliary thrust cylinders and the finished
• Phase III. The grippers set to work and with the support of tunnel walls
and working shaft, the tail shield comes into the ground in succession.
segments, the DS-TBMs can cope with almost all kinds of ground.
• Phase IV. Normal excavation procedure. The TBM is driven ex-
clusively by the gripper system. With the segments installing,
backfilling is conducted right after the installation.
2.1. DS-TBM tunnel construction process
• Phase V. The last excavate step before the cutterhead comes into the
shaft. Phase V differs from Phase IV in that there is no tunnel face
The tunnel construction process by DS-TBM can be divided into during this step.
eight phases, as illustrated in Fig. 2.

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Table 3
Calculation parameters for surrounding rock.

Item Country rock Lining concrete Back filling

Model Strain-Softening Mohr-Coulomb Mohr-Coulomb


Young’s Modules 18.9 GPa 28 GPa 1 GPa
Poisson ratio 0.23 0.167 0.3
Cohesion 15.6 MPa 2.73 MPa 15.6 MPa
Friction angle 25.8° 54.4° 25.8°
Residual cohesion 7.4 MPa – –
Residual friction 39° – –
Equivalent plastic strain 0.45 – –
threshold for cohesion
Equivalent plastic strain 0.9 – –
threshold for friction
Tension strength 1.5 MPa 1.78 MPa 1.5 MPa
Density 2630 kg/m3 2500 kg/m3 2400 kg/m3
Permeability coefficient 6 × 10−4 cm/s 1 × 10−7 cm/s 3 × 10−4 cm/s

• Phase VI. The cutterhead and front shield are gradually pushed into 2.2. DS-TBM parameters
the working shaft and removed. During this phase, the gripper
system provides the driving force. According to the components mentioned above, a simplified DS-
• Phase VII. The gripper shield then enters the working shaft and TBM sketch was proposed as shown in Fig. 3. The main features of the
shifts the responsibility of driving to the auxiliary thrust cylinders, TBM are listed in Table 1. Relevant parameters were identified using
which are supported by the finished segments. the comprehensive consideration of the TBM used in the Jinping II
• Phase VIII. The tail shield is jacked into the shaft in succession by Hydropower Station (Stephen et al., 2009), the parameters listed in
the auxiliary thrust system, whereafter the tunnel is complete. previous papers (Zhao et al., 2012, 2014; Rohola et al., 2014; Zhao,

Fig. 4. The cohesion and friction angle vs the plastic internal variable.

Fig. 5. Model sketch.

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Fig. 6. Weight distribution of the TBM ma-


chine.

2011), and publicity materials issued by Herrenknecht (see Jinping marble based on the Mohr-Coulomb yield criterion have been
Tables 2 and 3). proposed by Zhou et al. (2010) and Yang et al. (2013). These can
identify and assess the main mechanical characteristics of the rock. In
3. Modeling the model, the CWFS (cohesion weakening-friction strengthening,
Hajiabdolmajid, 2001) model was adopted, and a simplified develop-
In this paper, Ansys 14.0 was used to build and mesh the model. ment trend of cohesion and friction angle with the plastic internal
variable is shown in the following figure.
3.1. Country rock modeling In Fig. 4, the plastic internal variable κ is defined as κ = ∫ dκ. To
take the confining pressure effect into account, following format of dκ
Practicable mechanical models of the elastoplastic coupling of was chosen.

Fig. 7. Sketch of the normal force component


between grippers and country rock.

(a) (b)

(c)

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

The model has four main constituents, the rock to be excavated, the
concrete lining, the back filling, and the surrounding rock. The con-
stituents were arranged as shown to simplify the simulation process.
The country rock was divided into 3 groups with same properties but
different boundary conditions: (a) the outer field and the upper area
(cyan); (b) the side areas (green); (c) the bottom area (red). Part c re-
presents the rock mass that supports the weight of the TBM machine.
This weight is actually parabolically distributed, but a uniform dis-
tribution was adopted for simplification, as shown in Fig. 6.
Part b represents the rock mass that support the grippers. On the
contact area between the grippers and the country rock, there are two
force components, the normal component and the axial component.
These provide the TBM driving force during the excavation and confine
the rock mass deformation to some extent. During the process, the force
components were applied as shown in Figs. 7 and 8.
As shown in Fig. 7, some researchers adopt a distribution form like
that shown in Fig. 7(a) (Zhao et al., 2012, 2014), in this paper, form
Fig. 8. Sketch of the axial force components. Fig. 7(b) was adopted. The reason for this is shown in Fig. 7(c). Because
of the displacement that the grippers towards the country rock, the rock
would bear a friction Ft, and a normal force Fn, so the actual force on the
2 rock mass would be F along the direction of the thrust cylinder.
de p: de p
dk =
3 As illustrated, the axial force components on the rock mass include
f (Pc ) the pressure from the cutterhead and the axial component of the in-
teraction force between grippers and rock mass.
Here, dep is the plastic strain deviation tensor, f(Pc) is a function of con-
fining pressure which can be obtained by data fitting of the cyclic loading
tests under different confining pressures. Moreover, κ was normalized by the 3.3. Calculation parameters
plastic internal variable at the beginning of the residual period. The value of
κφ was determined as 0.6–0.8 by analyzing the test data. In simulation process, the mechanical and seepage response can be
During the simulation process, the strain-softening model was tai- obtained with different input data of geo-stress and groundwater.
lored to the surrounding rock. The cohesion and friction parameters Combined with Jinping tunnel engineering, the following data were
were evaluated using ctable and ftable with the values obtained by adopted for the simulation.
cyclic loading tests. Different materials were included in the simulation process, and the
model and parameters are listed as follows.
3.2. Model construction
4. Hydro-mechanical coupling simulation process
To reduce the number of elements in the model, it was not meshed
uniformly. In the near scope of the tunnel, a cylinder was employed to Groundwater activity plays an important role in the mechanical
reach a relatively fine mesh. A coarser mesh was adopted in the outer behavior of the surrounding rock, especially in the behavior of soft
field of the model. The sketch and size of the model are shown in Fig. 5. rocks whose mechanical properties can be substantially weakened, like

Fig. 9. Vault displacement trend over calculation steps.

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Fig. 10. Maximum unbalanced force trend vs calculation steps.

chlorite schist (Zhou et al., 2011, 2014) and sandstone (Wasantha and Kf
M=
Ranjith, 2014). In addition, high pore pressure can cause some com- n + (α−n)(1−α ) Kf / K
plicated reactions in surrounding rock, such as increases in creep ca-
pacity (Huang et al., 2010) and in stress intensity factor (Song et al., For saturated samples, s = 1, and the constitutive equation can be
2016). Therefore, it’s necessary to take the groundwater condition into simply expressed as follows:
account during the excavation simulation process. 1 ∂p ∂ζ ∂ε
= −α v
M ∂t ∂t ∂t
4.1. Theoretical background

(d) Fluid transportation equation (Darcy’s law):


In FLAC3D, the materials are assumed to be isotropic, porous, sa-
turated with lightly compressible fluid medium, and undergoing a slow k
v=− · ∇p
and subtle deformation process (Li et al., 2016). The formulation of ρf g
coupled deformation-diffusion processes is performed within the fra-
mework of the quasi-static Biot theory in FLAC (FLAC3D user’s manual).
Based on the linear-elastic hypothesis, the following equations can be (e) Continuity equation:
consolidated. ∂ζ
−∇ ·v + qv =
∂t
(a) Equilibrium equation:
Here, qv is the volumetric fluid source intensity.
∇·σ t + F = 0
(f) Compatibility equation:
(b) Terzaghi‘s effective stress principle: 1
ε= (∇u + ∇uT)
σ t = σ e + αpI 2

Here, α, the Biot coefficient, is defined as the ratio of the fluid vo-
lume gained (or lost) in a material element to the change in the volume 4.2. Numerical approach
of that element when the pore pressure changes. For an ideal porous
material, α can be computed using K and Ks (the drained bulk modulus A fully coupled model has been adopted in this project. Some
and the solid component bulk modulus, respectively) through parameters must be determined before the program was run. One is the
α = 1 − K/Ks. number of substeps needed for both mechanical and seepage compu-
tation, and the other is the number of steps needed per excavation
(c) The constitutive equation: stroke.

1 ∂p n ∂s 1 ∂ζ ∂ε
+ = −α v 4.2.1. Mechanical substeps
M ∂t s ∂t s ∂t ∂t
Before the TBM excavation program is initiated, a same-sized but
Here, ζ is the variation in fluid content or variation in fluid volume simpler tunnel construction simulation project was performed to esti-
per unit volume of porous material due to diffusive fluid mass transport, mate the development of vault displacement over time as measured by
and M is the Biot modulus and s is the saturation. M is defined as fol- the number of steps in the calculation process. In this process, a tunnel
lows: was excavated simply in 45 steps using “model null” commands. The

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Table 4
Development of displacements of the monitoring points on the tunnel wall over excavating strokes in different directions.

Excavation sketch

0 5 10 15 20 25 30 35 40 45

Vertical_up (0, 22.5, 6.3)

Diagonal _up (4.5, 22.5, 4.5)

Horizontal (6.3, 22.5, 0)

Diagonal _down (4.5, 22.5, −4.5)

Vertical _down (0, 22.5, −6.3)

curve of the development of the vault displacement is plotted in Fig. 9. the model during the excavation. After 300 steps, the maximum un-
According to reports of Jinping division tunnels, the majority of balanced force reached 3585.1661 kN. As With the mechanical force
vault displacement takes place during the excavation process (Lu et al., ratio approaches 1 × 10−5, the maximum unbalanced force came to
2015). Because the majority of the total displacement was achieved in 206.14215 kN. Correspondingly, the mechanical ratio threshold of the
300 steps during the excavation period in numerical simulation, we maximum unbalanced force can be calculated using the following
determined 300 to be a suitable number of mechanical substeps. In equation.
addition, the mechanical ratio should be limited as a supplementary
1 × 10−5
restraint. mechanical ratio threshold = × 3.585 × 106 = 1.739 × 10−4
2.061 × 105
Fig. 10 shows the development of the maximum unbalanced force of

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Fig. 11. Displacement contour of the midsection (y = 22.5 m).

Excavation Boundary

As shown in Table 4, deformation characteristics can be concluded


4.2.2. Seepage substeps as:
Strictly, for a fully coupled simulation, the mechanical and flow
analysis should be performed against each other step by step. To satisfy (1) The primary deformation direction was radial, secondary was axial
the mechanical force ratio limitation in each excavation stroke, a value (excavation direction), followed by tangential.
of 10 was substituted into the seepage substeps, and following format (2) With 20 m/d advance rate of TBM, the displacements started to
was used according to the FLAC3D V5.0 user’s manual increase about 1D ahead (D, excavation diameter).
(3) Along the direction of excavation, the deformation first increased
set mech ratio 1.739e−4 and then decreased, and gradually returned to zero as the tunnel
set mech subs 300 auto broke through the monitoring section.
set fluid subs 10 (4) Because of gravity, the deformation was not vertically symmetrical,
as illustrated in Fig. 11.
4.2.3. Calculation steps
During the construction of the Jinping II Hydropower Station Water The displacements along the monitored directions versus the depth
Diversion Tunnels, the greatest monthly advance was 683 m (Liu et al., of embedment in the midsection are shown as follows.
2016). In this way, the real time required for each excavation stroke can As shown in Table 5 and Fig. 12, findings were as follows:
be determined as 4300 s (30 d × 24 h/d × 3600 s/h–600 m = 4320 s/
m) in this project. (1) Magnitudes of the displacements induced gradually with the em-
In FLAC3D, “step” and “solve age” are both available to define the bedment depth increasing. The deformation scope of the country
calculation process. The value assigned to the solve age is actually the rock achieved 35 m (about 3D) in the radial direction when the
flow time and not the real time, except the facticity of the fluid para- tunnel excavation was complete.
meters can be guaranteed completely (FLAC3D user‘s manual). By set- (2) The deformation rate stayed relatively high during the tunnel face
ting the time step to 1, a “step 4300″ command was adopted in the located in the range of 7–8 m (about 0.5 D–0.6 D) to the monitoring
process. section.
(3) The axial deformation along the excavation direction remained
oriented towards the tunnel face and gradually returned to zero
5. Results
when the tunnel broke through the monitoring section.
The monitoring points were arranged in different directions (verti-
5.2. Pore pressure
cal_up, diagonal_up, horizontal, diagonal_down, vertical_down) in the
midsection plane (y = 22.5 m). There were 47 points with 1 m inter-
The development of pore pressure over the excavation strokes and em-
vals distributed in each direction.
bedment depth at the monitoring points are shown as Fig. 13 and Table 6.
As illustrated above, the features can be summarized as follows.
5.1. Deformation
(1) The pore pressure with the same embedment depth at different
The displacement values of the monitoring points on the tunnel wall directions shows the following: vertical_up < diagonal_up <
versus the excavating strokes are shown in Table 4.

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Table 5
Distributions of displacements along different directions of the monitoring points on the midsection with different excavation strokes.

Vertical _up (0, 22.5, 6.3)

Diagonal _up (4.5, 22.5, 4.5)

Horizontal (6.3, 22.5, 0)

Diagonal _down (4.5, 22.5, −4.5)

Vertical _down (0, 22.5, −6.3)

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Fig. 12. Y component of the displacements (m) at horizontal direction on the midsection (y = 22.5 m, z = 0) versus the embedment depth (m).

Fig. 13. Pore pressure development over excavation strokes on the midsection of the tunnel wall on the midsection (y = 22.5 m).

horizontal < diagonal_down < vertical_down, which means the excavation on deformation is about 3D, and that of pore pressure is
pore pressure isogram is egg-shaped, as shown in Fig. 14. about 2.5 D–3 D along the cross section.
(2) The depth of influence of pore pressure associated with the tunnel (4) A relatively high deformation rate was reached when the tunnel
construction on the midsection can be determined to be approxi- face came into 0.5 D ahead and 1 D after the monitoring section.
mately 30–35 m (about 2.5–3 D).
(3) The depth of influence of pore pressure influence associated with 6.2. Discussion
tunnel construction on the axial section is approximately 30 m
(2.5 D), as shown in Fig. 15. Based on the conclusions outlined above, some specific advice can
be proposed.
The development of pore pressure is illustrated in Fig. 16.
(1) During the excavation, the deformation and pore pressure of the
6. Discussions and conclusions rock mass within 3D around the tunnel wall should be paid more
attention.
6.1. Conclusions (2) Advanced monitoring of displacement and of the development of
pore pressure should be adopted in 2.5 D ahead the tunnel face.
In this paper, a 3D model for solid-flow coupling simulation of (3) Specific shoring projects should be chosen based on the asymme-
double shield TBM excavation was established. By analyzing the dis- trical distribution of displacement and pore pressure around the
placement and pore pressure developments at monitoring points, the tunnel.
following conclusions can be drawn.
In this paper, some modifications are still necessary.
(1) The deformation was as follows: tangential < axial (excavation
direction) < radial. The pore pressure was as follows: verti- (1) Considering the calculation efficiency, the grid size was not fine
cal_up < diagonal_up < horizontal < diagonal_down < vertical_- enough in the outer domain, which led to the roughness of dis-
down, which gave an egg-shaped pore pressure isogram. placement curves.
(2) As TBM advances at a rate of 20 m/d, the scope of influence scope (2) Because the rockmass was chosen to be the main research object,
of excavation on deformation is about 1 D, and the scope of influ- TBM was here simplified as stresses and forces to the coutry rock in
ence of pore pressure is about 2.5 D in the axial direction. this paper. The interaction between TBM and surrounding rock was
(3) During the tunnel construction period, the depth of influence of not very comprehensive.

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Table 6
Pore pressure distribution in different directions at the monitoring points on the midsection with different excavation strokes.

Vertical _up (0, 22.5, 6.3)

Diagonal _up (4.5, 22.5, 4.5)

Horizontal (6.3, 22.5, 0)

Diagonal _down (4.5, 22.5, −4.5)

Vertical _down (0, 22.5, −6.3)

Fig. 14. Pore pressure contour at 45th excavation stroke on the


midsection (y = 22.5 m).

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H. Zhou et al. Tunnelling and Underground Space Technology 71 (2018) 1–14

Fig. 15. Pore pressure contour at 5th excavation stroke on the axial
section (x = 0 m).

Fig. 16. Pore pressure development process.

Acknowledgements Li, G., Tang, C.A., Li, L.C., Li, H., 2016. A novel finite element two-step solution scheme
for fully coupled hydro-mechanical processes in poroelastic media. Comput. Geotech.
80 (C), 178–189.
This project received financial support from the National Program Liu, Q., Huang, X., Gong, Q., Du, L., Pan, Y., Liu, J., 2016. Application and development of
on Key Basic Research Project of China under Grant No. 2014CB046902 hard rock TBM and its prospect in china. Tunn. Undergr. Space Technol. 57, 33–46.
Lu, Y., Shen, Y.X., Wu, Z.M., Li, M., 2015. Analysis Report of Water Diversion Tunnel
and from the National Science Foundation of China under Grants Nos. Monitoring Results in Jinping II Hydropower Station in Sichuan Yalong River.
51427803, 51279201, and 51404240. Huadong Engineering Corporation Limited.
Maghous, S., Bernaud, D., Couto, E., 2012. Three-dimensional numerical simulation of
rock deformation in bolt-supported tunnels: a homogenization approach. Tunn.
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