Tunnel Excavation by Tunnel Boring Machine (TBM) in

Bheri Babai Diversion Multipurpose Project (BBDMP)

Er. Jagadiswar M. Shrestha

(MSc in Structural Engineering)
June 7, 2019
 Content of Presentation
A. Excavation by Tunnel Boring Machine (TBM)
• Brief Information on BBDMP
• Starter Tunnel (150m) Excavation by Drilling
& Blasting Method (DBM)
• Information about TBM
• Tunnel Excavation by TBM

B. Quality of Precast Segment Production

C. Scope for Metro
Bheri Babai Diversion Multipurpose Project (BBDMP)
Overall Concept: 1.Diversion Component
Two Main A. Headworks
B. Headrace Tunnel
Components
C. Powerhouse
2.Irrigation Component [47MW with Q(40m3/s)
& H(152m)]
Babai Irrigation Project
(Ongoing, 51000ha year
Round Irrigation)

Benefit/year(based on 2011)
Kohalpur

1. By Irrigation :NRs 2.20 Billion

2. By Electricity :NRs 2.80Billion
3. No loss of Land & Forest
 Two Special Features of BBDMP in Nepal
• First Inter Basin Water Transfer (IBWT) Project
Water from water Surplus
river basin
to
water Deficit river basin

• Tunnel Excavation by Tunnel Boring Machine (TBM)

(Only one Audit tunnel at 6km in 220m below, hence DBM is difficult)

Harre Danda
Toli Khola
820m
Bheri
river
Babai 220m
river
Tunnel Slope 1:335
 IBWT Projects - Overall Perspective

Sunkoshi-Marin DMP

1. BBDMP (Implementation) 5. Kaligandaki-Nawalparasi

2. Sunkoshi-Marin (Feasibility Study) 6. Trishuli-Chitawan
3. Sukoshi-Kamala (Kosi High Dam) 7. Bhaluwang –Kapilbastu
4. Kaligandaki-Tinau 8. Madi-Dang
 Profile & Geology of Tunnel
Harre Danda
Pond Level (Bheri
Toli Khola river) = 461 m

820m

220m
Tunnel Length = 12 Km
Discharge=40m3/s Diameter (Finished) = 4.2 m
Tunnel Slope 1:335
Bheri river

Tailrace Level (Babai

river) = 309 m 152m (G Head)
135m (N Head)
Babai river
 1. Employer
A.Construction of Headrace Tunnel
: Department of Irrigation,
Bheri Babai Diversion Multipurpose Project
2. Consultant : Geodata Engineering S.p.A., Italy in association with
Sustainable Infrastructure Development Foundation (SIDeF), Nepal
3. Contractor : China Overseas Engineering Group Co. Ltd., China (COVEC)
4. Contract No. : Civil 01/HRT/BBDMP
5. Date of Commencement : Jun 4, 2015 (BS 2072 Jeth 21)
6. Date of Completion : Mar 28, 2020 (BS 2076 Chaitra 15)
7. Agreement Amount : NRs. 10,569,732,141.52 (including VAT)
8. Tunnel Length : 12.208 KM
9. Tunnel Diameter (Finished) : 4.20 m
10. Tunnel Excavation Method : Mechanised Tunnelling by Tunnel Boring Machine
11. Main Works : Access Road, TBM Platform, TBM Entry Portal,
Headrace Tunnel, TBM Exit
12. Tunnel Excavation by DBM : 150m
13. Lining Works by TBM : 12.058 km Pre-cast Concrete Segmental Lining
51432m3 (M50), Rebar (5654MT)
13.Breakthrough of 12.208kM : Apr 16,2019 (Baisakh 3, 2076) .

B.Construction of Headworks & Powerhouse

Contract bid will be submitted within
10 June 2019 (BS 2076 Jeth 27)
 Project Construction Site
(Project site: 28km North from Kohalpur,
Surkhet District, Province No. 6)

TBM
Platform

Employer’s
Camp
弃土场
Segment
Contractor’s Plant
Camp
Dumping
Site
Crushing Quarry
Plant Site
 TBM Platform, Employer’s Camp & Contractor’s Camp

TBM
Platform
TBM
Platform

Employer’s
Camp
Employer’s
Contractor’s Camp
Camp
Contractor’s
Camp
Segment
Plant

Google Map
(28o21’30”N,81o43’10”E)
 Employer’s Camp

Office

Quarter
 Segment Plant
Segment Plant Cement Store

Lab & Mechanical Store Aggregate Store

General Store

Curing
Diesel Tank

Seg
Generator Labor Camp1

m
Ts

ent
ank

Sto
rag
e
Yar
Segment Labor Camp2

d
Plant

Cotractor’s
Camp
 Tunnel Excavation by DBM vs TBM
DBM
Shotcrete, Shotcrete with wiremesh,
Rockbolt, Lattice girder, RCC etc
Construction Period-Long
TBM
Precast Segment erection with pea-gravel &
grouting for extra excavation, Probe drilling.
Construction Period-Short

Tunnel Excavation by TBM costs about double of DBM, but is about 3 times fast in
construction (average 28.65m/working day in BBDMP along with RCC Segment)
 Entry Portal - Plan

Entry Portal -L-Section

49m

130m

25m
 Tunnel Excavation by DBM & TBM
Starting Point of TBM Tunnel

TBM Tunnel after 150m

Surge Tank

150m DBM Tunnel

150m DBM Tunnel Start Pt. of TBM Tunnel TBM Tunnel

Preparation of Inititial 150m by Drilling & Blasting

Heading

Benching
Tunnel Excavation by DBM Method (150.7m)
Started on Jan 1, 2017 & Completed on June 2, 2017

49m
15m TBM Front Covered Part out of 274m
 Transport of TBM
Arrival at Kolkata Aug 5,2017
Vehicles (total 53) arrived at
Nepal Customs on Aug 26, 2017

Max Load = 67t

Total Load = 1056t

TBM arrival at job site Sep 13,2017

Step-in Program on Sep 27, 2017 (Fulpati,2074)
1 month before than schedule
Tunneling (Excavation) All digital input for
operation from
Operator’s console
• Excavation (Mechanical,
Hydraulic, Electrical,
Electronics
• Vertical, Horizontal,
Curvature Vertical Align
Horizontal Align
Section Monitoring of excavated Surface (Type V)
(Oct 18,2017 to Oct 29,2017)
Mucking
• Muck is disposed
from TBM by
conveyor belt to
muck cart
• Muck cart dispose
at mechanized
disposal equipment
• Loaded to disposal
truck by backhoe
Erecting the Bottom and Lateral Segment
1st time Water Ingressing at 1175m on Dec 27,2017
with 65 Ltr/s
2nd time water ingress at ch 1+337 with discharge of
75 Ltr/s on 2018 Jan 6,
suppressed by continued excavation with less speed
Bheri Thrust = Highest Risk Zone

5900m 6300m
400m
 TBM Stucked at Ch 8+588
Harre Danda
Pond Level
Toli Khola (Bheri river)
= 461 m
Tailrace Level 820m
(Babai river)
= 309 m 220m
Tunnel Length = 12 Km
Discharge=40m3/s Diameter (Finished) = 4.2 m
1st time TBM Stuck at Ch. 8+588 on 2018 Oct 15 due to unequal rock at face
along with little water ingress & Strike nearly parallel to tunnel alignment.
Resumed excavation after 8 day later by making bypass tunnel

TBM side face of Shield

Bypass Tunnel
Bypass Tunnel
 2nd time TBM Stuck at Ch. 8+606 on 2018 Oct 24 by top slab collapse due to
loose cement and water inflow & Resumed on the same day after 3m pre-
grouting with polyurethane chemical injection on top slab. Excavation
continued but deviate alignment towards right side soft rock up to 90cm.

Polyurethane
chemical & grout
foam

Drilling work for polyurethane chemical injection

 Daily Tunnel Excavation by TBM
(15 Oct 2017 to 16 Apr 2019)
Ch. 0+150.7 of Ch. 12+206.2
Breakthrough on Apr 16, 2019
70
TBM Excavation Stoppages Best day : 61.77m (2 Aug 2018)
1. 19Oct-29Oct,17: For TBM trial test and lack of segment accessories Average/working day : 28.65m
2. 19May-8Jun,18: Tunnel Crown Grouting
3. 8Jul -13Jul,18: TBM maintenance before Bheri Thrust zone location
Average/day : 23.52m
60 4. 30Aug- 7Sep,18: California Switch installation at Ch.6+500 Average Monthly : 709m
5. 11Sep-14Sep,18: Rotary Dumper repair Best Week : 324.53m (2018 Aug 2-Aug 8)
6. 16Oct-22Oct,18: TBM Stuck at Ch.8+588 Best Month : 1062.67m (Aug, 2018)
7. 7Nov- 9Nov,18: Tihar Festival
Length (m)

50 8. 3Nov-18Nov,18: Rotary Dumper repair

9. 4Apr-15Apr,19: Preparation for breakthrough

40

30
Av./day=23.52m

20

10
51
11
21 61 71 81 91
31 41
0
15-Oct-17
25-Oct-17
4-Nov-17
14-Nov-17
24-Nov-17
4-Dec-17
14-Dec-17

13-Jan-18
23-Jan-18
2-Feb-18
12-Feb-18
22-Feb-18
4-Mar-18
14-Mar-18
24-Mar-18

13-Apr-18
23-Apr-18

13-May-18

2-Jun-18

22-Jun-18
2-Jul-18
12-Jul-18
22-Jul-18

11-Aug-18
21-Aug-18

10-Sep-18
20-Sep-18
30-Sep-18

30-Oct-18

19-Nov-18
29-Nov-18
9-Dec-18
19-Dec-18
29-Dec-18
8-Jan-19
18-Jan-19
28-Jan-19
7-Feb-19
17-Feb-19
27-Feb-19
9-Mar-19
19-Mar-19
29-Mar-19
8-Apr-19
24-Dec-17
3-Jan-18

3-Apr-18

3-May-18

23-May-18

12-Jun-18

1-Aug-18

31-Aug-18

10-Oct-18
20-Oct-18

9-Nov-18
Date
 Tun nel Excavation b y TBM (

2000
4000
6000
8000

0
10000
12000
14000
16-Oct-17
1-N ov-17
17-N ov-17
3-D ec-17
19-D ec-17
4-Ja n-18
20-Jan-18
5-Feb-18
21-Feb-18
9-M a r-18
25-M a r-18
10-Apr-18
26-Apr-18
12-M a y-18
28-M a y-18
13-Jun-18
29-Jun-18
15-Jul-18
31-Jul-18
16-Aug -18
1-Sep-18
15 Oct 2017 to 16 Apr 2019

17-Sep-18
3-O ct-18

Date
19-Oct-18
4-N ov-18
20-N ov-18
6-D ec-18
22-D ec-18
7-Ja n-19
23-Jan-19
(Target of Excavation upto 12 Nov 2019)

8-Feb-19
24-Feb-19
12-M a r-19
28-M a r-19
13-Apr-19

16-Jun-19
Daily Cumulative Tunnel Excavation Target vs Progress by TBM
 Segment Stacking
(Total 34550)

Tolerance of 1400mm Segment width is 1mm and 3mm for other

dimension
 Length (m)

10000
12000
14000

0
2000
4000
6000
8000
16-Oct-17
1-Nov-17
17-Nov-17
3-Dec-17
19-Dec-17
4-Jan-18
20-Jan-18
5-Feb-18
21-Feb-18
9-Mar-18
25-Mar-18
10-Apr-18
(Upto 16 Apr, 2019)

26-Apr-18
12-May-18
Tunnel Segment Length

28-May-18
13-Jun-18
29-Jun-18

Date
15-Jul-18
31-Jul-18
16-Aug-18
1-Sep-18
17-Sep-18
3-Oct-18
Tunnel Segment Length vs Tunnel Length

19-Oct-18
4-Nov-18
Tunnel Length

20-Nov-18
6-Dec-18
22-Dec-18
7-Jan-19
23-Jan-19
[Tunnel Segment Length=(No. of segment/4) X1.404m]

8-Feb-19
24-Feb-19
12-Mar-19
28-Mar-19
13-Apr-19
Breakthrough Ceremony by Prime Minister in
presence of Ambassadors of USA & China
After Breakthrough (Intake Site Bheri)
2019 Apr 16 (2076 Baisakh 3)
 End Tunnel (Intake site, Bheri)
from outside & inside of Tunnel
Factors contributing to early completion of Tunnel
• Implementation by Planning team
• Positive working attitude of Contractor & nature of work
• Better geology condition than anticipated
(not necessary probe drilling, ground engineering works, etc.)
• Smoothly crossed the Bheri Thrust Zone
• Contractor’s ownership of the TBM
• Negligible effect of Strikes (due to labour, local & general)

Special Features of BBDMP

• Completion within Time frame (7.5 month ahead)
• Completion within Contract amount (about NRs.1.25 billion less)
• With better quality of works
• Negligible claim
• Confidence boost for new projects
 Tunnel excavation by TBM vs DBM

Parameter TBM Tunnel DBM Tunnel

Cost/km About 78 crores (BBDMP) About 40 crores (RGHEP)

Transport of TBM Difficult for Remote Not needed

Tunnel length About >8 km for economy Any length

Segment Plant Needed Not needed

Construction Period TBM tunnel is about 3 times faster than DBM

Concrete Precast segment Cast in situ

Quality Control Effective Difficult

No payment is made for entry portal in the contract document. Once the segment
is placed inside the tunnel by TBM, the machine cannot get back and the only exit
route is the other end of the tunnel reached after completion. Hence chance of
contractor leaving without completion of tunnel due to any reason is scarce.
Head Works model from upstream
Head Works model from downstream
Powerhouse
Powerhouse
Brief Description on Quality of Works

Co m p . S t re n g th (M P a )

Compressive Strength of Precast Segment (M50)

(Total cube casted-13836no.)

80 7 day Polynomial (7 day) 28 day

Polynomial (28 day) Design 28 day Strength
75
70
65
60
55
50
45
40 Average 7day=53.52MPa; Average 28day=67.70MPa

35
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
Concrete Sample Id.
 Performance based on Average & Multiplication
Concrete Quality If students had got
Cement Quality 100% 95% such marks, their
× × result would have
Aggregate Quality 100% 95% been distinction

× ×
Batching & Mixing 100% 95%
× × But, this principle
Transportation & Pouring 100% 95% does not apply
× × here!
Compaction 100% 95%

× ×
Finishing 100% 95%
× × “It shows clearly that
why quality control is
Curing 100% 95%
important and sensitive
from the level of each
Concrete Structure 100% 70% constituents to the level
=

upto reqd. strength”

Steel Bar (Fe 500D) Test
 Crushing & Screening Plant (BBDMP)

Impact Crusher Cone Crusher Jaw Crusher

 Quality Control of Precast Segment
Cycle of Pre-cast Segment Production
from 28 no. Mould (4Segment/ring of 1.4m wide)
Tolerance-1mm for width & 3mm for other

20 nos. mould in steam chamber

 Curing Water Checking pH value

Temp. Control for Shrinkage of Segment in night

Difference of Temp. between Segment & Water Temp. before curing <25 oC
 Compressive Strength of Precast Segment (M50)
(Total cube casted-13836no.)
80 7 day Polynomial (7 day) 28 day Polynomial (28 day)
Design 28 day Strength
75

70
Comp. Strength (MPa)

65

60

55

50

45

40
Average 7day=53.52MPa; Average 28day=67.70MPa
35

30
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400

Concrete Sample Id.

 Meaning of Metropolitan City
City having “Metro” service
Option for Traffic Congestion
Priority for Mass Transit
Road expansion alone will not solve traffic congestion; an urban rail might do better
From long term vision, Metro will be better solution for fast service with huge traffic than any
other transport media like long vehicle, mono rail or sky train etc. however initial cost is high

Features of the Metro

Equal facility for all level person
Reduce the trend of purchasing motorbike
Save millions of rupees to buy petroleum products by reducing surface vehicle
Enhanced traffic management
Reduce Environment impact, sound pollution, save existing land & buildings etc
Reduce population centralization in core city
Latest technology with sustainability for long period
Very less disturbance to people during construction
 Special Features in Road Tunnel other than
Hydro Tunnel
• No Leakage (100% water proof)
• Illumination inside tunnel shall be at least that of natural
daytime
• Proper ventilation shall be provided (Fresh air inside without
polluted exhaust air)
• Escape Tunnel around every 3km
• Special high class concrete
• Automatic indication with red light for Squeezing
• Emergency System Arrangement
– Backup Light dedicated 24 hr
– 24 hr ready for rescue operation in case fire or accident
– Communication system without break
 Delhi Metro

Started at 25 Dec 2002 from Red Line

Expanded up to 231km till 2016
Study group of KTM Metro
Planning of Metro in Kathmandu

Source:Dr. Binod Lal Amatya

 Proud of being an Engineer

Lawyer -income increases with increase in Crime & Litigation

Doctor -income increases with increase in Diseases & Illness
Engineer-income increases with increase in
Prosperity of People & Nation

Identification of Lawyer - Files in hand

Identification of Doctor - Stethoscope in hand

Identification of Engineer - Nothing in hand, but

everything in mind
 Headworks of SIP, Banke

Concrete :167,810m3
Cube Crushed:20,178no.
Rebar used : 8,011 MT
NTC Building, Sundhara

Concrete :42,348m3
Cube Crushed:5,580no.
Rebar used :3,524 MT

CIAA Building, Tangaal Headworks of RJKIP, Kailali

Some Structures Designed by the Author

Thank you for your kind attention