Downtown Line Stage 2 -

C919 Design and Construction of Stations and

Tunnels at Botanic Gardens and Stevens

An Introduction to Bored Tunneling

Supervision
I. Introduction
1. Geological Profile and Alignment
2. EPB TBM General Details
3. Video on EPB general operation

II. Tunnel Supervision General Overview

1. Tunnel Safety
2. TBM Excavation
3. Ring Building
4. Grouting
5. Recording and Reporting
I. Introduction

1. Geological Profile and Alignment

I. Introduction

1. Contract 919 – Design, construction and completion of

the stations at STV, BTN and connecting bored
tunnels between the stations.
2. Two cross passages along the tunnel route will be
constructed by NATM method.
3. Geological profile – Kallang formation and Bukit
Timah Granite formation.
Bukit Panjang Bound (BPB)
Bukit Panjang Bound (BPB
Bukit Panjang Bound (BPB)
Expo Bound (EPB)
Expo Bound (EPB)
Expo Bound (EPB)
I. Introduction

2. EPB TBM General Details

Earth Pressure Balanced Machine (EPB)

Cutterhead Excavation Compressed Air Lock

Chamber

Pressure Screw
Bulkhead Conveyor
Principals of TBM Tunneling

Increase / Lowering of Shield Advance Rate

Increase / Lowering of
Screw Discharge Rate

Water Earth
Pressure
EPB General Details
EPB TBM General Details

Soil Conditioner Test Segment Erector Test

EPB TBM General Details

TBM Backup Cars TBM Backup Cars

I. Introduction

3. Video on TBM General Operation

II. Tunnel Supervision General Overview:
1. Tunnel Safety
2. TBM Excavation
• Operating face pressures
• Muck reconciliation
• TBM alignment
• Review of instrument and monitoring readings
3. Ring Building
• Ring tolerances
• Segment bolts tighten
• Recheck ring tolerances and damage after TBM shove out of
tailskin
4. Grouting
• Ensure continual primary grouting
• Proof drilling and secondary grouting
5. Recording and Reporting
II. Tunnel Supervision General Overview

1. Tunnel Safety
Tunnel Safety
Monitor Gases (CO2, CO, O2, CH4, H2s) and temperature in tunnel at every 4Hrs

Ventilation System.
Tally board (5.7cum/min/worker
and Temperature max
Emergency Self Rescuer 28°)

Obey all Safety warning

signs, Visual warning and Fire
Audible alarm for extinguishers Water hose reel
hazardous operations First aid
Emergency alarm
and Intercom
 Tunnel Safety
Warning/Speed limit Signs. Sirens and
Traffic lights fitted along track when two
locomotives are in operation on single
track

Manchester Gates Fire Drill

provided at Pit bottom
and at end of Backup to
stop runaway locomotive.

Provide Rail Colour coding for

stopper at end of Lifting Gear &
the track. Electric equipments

wheel chocks shall be

placed, in addition to
hand brakes, when Tool Box meeting Locomotive shall be fitted with camera
locomotive is & PGI so that driver can see in front.
standby. Locomotives are also fitted with
flashing lights and siren.
II. Tunnel Supervision General Overview

2. TBM Excavation – To control Sink Holes!

TBM Excavation – Operator’s Instruction Sheet
TBM Excavation – Operator’s Instruction Sheet

1. The advance mode

2. The minimum face pressure allowed
3. The maximum face pressure allowed
4. Cutterhead rotation speed
5. Penetration
6. Maximum thrust force
7. Minimum thrust force
8. Conditioning to be used
9. Maximum number of skips
TBM Excavation – Muck Reconciliation

Muck Reconciliation

• Theoretical Volume per Ring : 47.7m3 ~ 48m3 (Solid)

• Volume of Skip : 6.8m3
• Therefore one shove of 1.4m (1 Ring) requires about 7
skips to fill or 200mm advancement per skip.
TBM Excavation – Muck Skip Record
TBM Excavation – Cutterhead Intervention
TBM Excavation – Face Pressures (EPB)
Operating Face Pressures
TBM Excavation – Face Pressures (BPB)
TBM Excavation – Cutterhead Intervention
II. Tunnel Supervision General Overview

3. Ring Building – Quality Control

Ring Building
• Segments will be sent in in sequence
• Before segments are unloaded from flat cars, a visual
inspection should be done to check for knocks or chip
offs in the segments
• The segments will be placed onto the segment feeder
which will then transfer the segments to the erector
• Each ring consist of 5 segments and a key
• After erector places the segment, impact wenches will
be used to install the bolts
• After the TBM tail skin leaves ring, the bolts are
retighten again
Ring Building
Specification and Tolerances

• Internal Diameter - 25mm

• Centre – 50mm
• Profile – 62.5mm
• Square and Plumb – 20mm
• Plane – 6mm
• Roll - ± 40mm
• Lips and steps- 5mm
Ring Building – Internal Diameter
C
L
Maximum
Internal Diameter decrease = 25mm
± 25mm from
design
diameter
Squat Ring

Total maximum
increase = 25mm
Ring Building – Centre and Profile
C
L
Ring Position
Maximum centre offset
(centre & from design position =
50mm
profile)

Axis

Maximum profile offset

from design position =
62.5mm
Ring Building - Square
Key Segments Ring is not square to the alignment

Alignment

Centreline

Maximum = 20mm
Square
Plan View of Right hand side is leading (Right
Tunnel Lining Lead)
 Ring Building -Plumb

Vertical Plumb Line

Plumb

Alignment
Axis Level

Side View of
Tunnel Lining
Ring Building - Plumb
Vertical Plumb
Vertical Plumb
Line
Line

Actual Axis
Level

Axis Level
Required

(Maximum = 20mm)
Overhang
Look Up (Maximum = 20mm)
Side View of
Tunnel Lining
Ring Building - Plane

Ring Plane

Maximum = 6mm
Ring Building - Plane

What happens if the ring is out of plane?

The lining may crack

Ring Building – Plane

What happens if the ring is out of plane?

Cracks in the tunnel

lining : The lining may crack
max 0.2mm
Ring Building – Roll

Ring roll
Maximum =
± 40mm

CL
 Ring Building – Roll

Pre cast tunnel lining Drilled holes

segment clash with
reinforcement
Drilled holes
avoid link
reinforcement

Drilling point or Effects of ring roll

dimple
Ring Building – Steps

Maximum = 5mm

Steps
Step in temporary
linings
Ring Building –Lips

Ring -2 Ring -1

Max lip = 5mm

Lip
Step

Lips
 Ring Building – Gaskets
Gasket
not sitting
Gasket correctly
spoiled
due to
contact
with Gasket
water at damage
tunnel d by
invert Gasket out of shove
gasket groove
rams
 Ring Building –Segment Handling

Stains on the rings caused by

timber spacers
Ring Building – Ring Inspection Sheet
II. Tunnel Supervision General Overview

4. Grouting
Grouting
• Primary grouting will be done continuously during
excavation through 4 grout slots at controlled
pressure (Minimally 2 grout slots)
• Triple wire brushes seal will prevent the grout from
leaking into the tail seal
• Secondary grouting to prove that the annulus is full
will be carried out within about 10 rings away from the
build area
Grouting - Primary

Grouting is done continuously

through the TBM tail-skin

TBM

Grout ports in
the tail-skin
Grouting - Primary

Pump grout until

set pressure is
reached and
record the
volume
Grouting - Primary

Tunnel lining
If the void is
can be pushed
not filled
out of shape
Grouting - Primary

If the void is
not filled
Grouting – Excessive Grouting

Key has been pushed by

excessive pressure
Grouting - Secondary
Usually undertaken within 20m of the last ring built.
Check on the primary grouting to see if there are any voids
behind the lining.
Void
Usually voids will be found in the crown but other areasin the
need to be checked crown to be
back grouted
Grouting - Testing
Flow Rate Test. Grout Bleeding Test.
Properties
Flow rate : 8-12 sec
Bleeding : 0-5 %
Gel time : ≤ 15 Sec

Gel Time Test.

II. Tunnel Supervision General Overview

5. Recording and Reporting

Recording and Reporting
• Start and finish time of excavation stroke including
stoppages and reasons for stoppages
• Ring no, chainage and key position
• All delays and reasons for delays
• Earth pressures readings at start, middle and end of
excavation stroke for cutter chamber and screw
• Quantity of material excavated
• Total advance for the shift and accumulative advance
• Number and location of any cutters changed
• Volume of grout injected per ring and the pressure, the
accumulative volume of grout for the shift
Recording and Reporting
• Volume, type and location of the soil conditioning
added
• General comments on the description of the excavated
material
• Record for the tunnel faces of line, level, square, roll
and plumb of the machine
• Quantity of tail seal grease consume per ring
• Any segment damage on completed rings
• The timing and nature of machine maintenance carried
out
Thank You