project and construction of underground stations and tunnels--.pdf
DESCRIPTION
Metro projectTRANSCRIPT
1
PORTO
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
PORTO
Project and construction of
Underground stations and tunnels U de g ou d stat o s a d tu e s
(TBM and NATM) in heterogeneous
masses for Metro do Porto.
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
António Viana da Fonseca ([email protected])
António Topa Gomes ([email protected])
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
2
Metro do Porto
Project and construction
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
System of Light Metro of the Metropolitan Area of Porto
The Project
Geological Conditions
Metro do Porto
INDEX
Tunnels:
- TBM (sellection and adaptations) and other solutions
- Monitoring and Control Tunnels
Underground stations:
- Cut and Cover: active support or unsupported shafts (arch effects)
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
pp pp ( )
- Cavern with access shafts (unsupported) and mining by NATM
Building Risk Analysis:
- Surveying Procedures (limits and alerts; reactions and solutions)
3
And there has been a
POPULAR MYTH
Metro do Porto
POPULAR MYTH
An underground metro would never be a reality
in Porto !!!
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
in Porto !!!
The granite is impenetrable?...
Metro do Porto
The Project
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
4
Reconvertion of more than
50Km of existing lines.
Construction of 13 km of
f li
Metro do Porto. Routes
surface new lines.
Construction of 7 Km of
tunneling new lines.
74 Stations with decks of 70m
length and 0,30m height.
Construction of 2 Principal
Interface Structures.
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
11 Underground Stations.
19 Rehabilitation and
modernization of existing
Surface Stations.
44 New Surface Stations.
Legenda:
1 - Túnel (Tuneladora)2 - Est. Heroísmo3 - Est. 24 de Agosto4 - Trindade (D . Redes p/ Trincheira)5 - Matosinhos - P .I. V ia Rápida6 - Matosinhos - D esvios Redes p/ V ia
9
Frentes de Obra activ as em Jan/2001
Fren tes de O b ra activas em O u t/2001Frentes de obra activas em FEV 2002
ou
nd
Sta
tio
ns
Metro do Porto. Routes
p7 - PMO Guifões8 - Ramal acesso PMO Guifões9 - Maia (Desvios Redes e P lataforma)
5
6
7 8
6
612
11
1314
15
Mai
n U
nd
erg
ro
Line S
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1
23
4
10
11 15
Tunneling new lines
Line C
5
Metro do Porto
Geological Conditions
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Metro do Porto. Geological Conditions
Distribution of Porto Granite
Iberian Granites
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6
Metro do Porto. Geological Conditions
Geological complexity of the region
CIZ – Central Iberian Zone; OMZ O M Z
PTSZ
Douro River
OMZ – Ossa-Morena Zone; PTSZ – Porto-Tomar Shear Zone; (1) Cenozoic cover deposits; (2) Cambrian – CIZ (Schist and Graywacke Complex); (3) Precambrian metassediments – OMZ; (4) Madalena granite (late orogenic);
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Z
OMZ
CIZ
21 3 4 5 6
orogenic); (5) Ermesinde granite (hybrid sin-tectonic); (6) Porto granite (peraluminous sin-tectonic)
Metro do Porto. Geological Conditions
Prevailling conditions of Porto Granite - “All Weathering Grades“
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
irregular geometry between weathered and sound rock mass
7
Metro do Porto. Geological Conditions
Erratic profiles of highly weathered to sound granitic masses
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Metro do Porto. Geotechnical Characterisation
Geomechanical Group
Weathering (W)
Fracturation (F)
GSI NSPT
Geomechanical classification & characterization
RQD NSPTFract.
Group (W) (F)G1 W1 F1-F2 65-85 -G2 W2 F2-F3 45-65 -G3 W3 F3-F4 30-45 -G4 W4 F4-F5 15-30 -G5 W5 n.a. - > 50G6 W5/W6 n.a. n.a. < 50G7 n.a. n.a. n.a. var.
Ru (Mpa) (kN/m3) mb s Ed (GPa)G1 90-150 25-27 7.45 6.9E-2 35G2 30-90 25-27 3 2 7 5E-3 10 7OC
K
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
G2 30-90 25-27 3.2 7.5E-3 10.7 G3 10-35 23-25 0.98 7.5E-4 1.0 G4 1-15 22-24 0.67 0 0.4
NSPT (kN/m3) c’ (Mpa) ’ (°) Ed (GPa)
G5 > 50 19-21 0.01-0.05 32-36 0.05-0.20G6 < 50 18-20 0-0.02 30-34 0.02-0.07G7 variable 18-20 0 27-29 <0.05
SO
ILR
O
8
Metro do Porto. Geotechnical Characterisation
Number of boreholes (1st phase):classical (drilled) and DPR (continuous parameter recording)
Work
Drilled Boreholes
Conventional rotary Parameters recording (DPR)
Nº Comp.(m) Nº Comp.(m)
LINE C 122 3522 18 592
LINE S 75 2068 11 288
LINE J 10 560 - -
Stations Line 'C' 74 1164 - -
Stations Line 'S' 117 3004 - -
TOTAL 398 10318 29 880
Work Conventional rotary Parameters recording (DPR)
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
10,5 m
17,0 m
26,4 m
Metro do Porto. Geological Conditions vs operation mode
Quality of Porto Granite andpossible alternative EPB operation modes
1. Granitic mass sound or slightly weathered, noweathered material in the discontinuities.
Operation mode-TBM
OP
EN
mo
de
2. Granitic mass with very weathered material infractures; these fractures may communicate withoverlaying parts of completely weathered granite.
3. Very weathered or completely weathered granite(almost granular soil with little or no cohesion).
4 Very weathered or completely weathered granite
NeC
LO
SE
Dm
od
e
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4. Very weathered or completely weathered granitewith blocks of the rock core.
5. Mixed conditions with both sound mass and comp-letely weathered granite appearing in the face.
In all cases the water table is above the tunnel crown
D
9
Metro do Porto. “Campanhã” Station - Assessment of Geology
g7 g6 g5 g4 g3 g2Line S
(underground)
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Metro do Porto. “Campanhã” Station - Assessment of Geology
g7 g6 g5 g4 g3 g2Line C
(underground)
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Metro do Porto. Geological Conditions
The Geological Model
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Features in weathered masses of granitic and other igneous rocks.
R. Fell et al. 1992 Weathering profile Begonha and Braga, 2002
Metro do Porto. Geological Conditions
Geology of Porto Granite“All Weathering Grades“
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Metro do Porto. Geological Conditions
Weathered Granite (left) underlaying Sound Granite (right) in Places
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Metro do Porto. Geological Conditions
fresh
weathered
fresh granite
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granite
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Metro do Porto. Geological Conditions
Multiple solutions
Diverse weathering
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Metro do Porto. Geological Conditions
Multiple solutions
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Metro do Porto. Geological Conditions
Mixed solutions
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Metro do Porto. Geological Conditions
Same station, North Side versus South Side
Unsupported shafts: the importance of waterlevel lowering
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Metro do Porto. Geological Conditions
North Side: Preparing the breakthrough of TBM
Jet-Grouting Type II
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Sou
th S
ide
Preparing the
“intrusion” of the TBM -
nails of fibreglass
Tunnels
TUNNELING BORING MACHINE
“Earth Pressure Balance”
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Metro do Porto. Geological Conditions for TUNNELING
Tunneling - assesment of geology
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Predicted geology for the Heroismo mined station, assessment by Transmetro
Tunnels. Geological and Geotechnical Conditions
Geological mapping at the face
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Metro do Porto. Tunnel geometry
D
A
DD
A
Geometry
A
C
B
C
LV
F+T
MV
CD
A
C
B
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INTERNAL GABARIT MINIMUM CURVES’ RADIOS MAXIMUM SCALES
- TBM 1: 7,80 m - Horizontal: 200 m - Scale: 140 mm
- TBM 2: 8,00 m - Vertical: 500 m
Gabarit: Gabarit taking the vehicule dynamics, Catenarie, Free passage (0.70m), tubes for
cables, Via (STEDEF type), Signals, Ilumination…
Tunnels. TBM - project
Project conditions
Tunneling internal diameter:
7.8 – 8.0m
Lined with a tapered universal ring:
1.4m long and 300mm thick
Consisting of :
6+1 pre-cast, reinforced concrete segments
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
The tappered rings allow:
a minimum radius of 200m
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Tunnels. TBM (EPB) - Ring Support
Supportin rings – a PUZZLE !!!
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Tunnels. TBM (EPB) - Ring Support
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Tunnels. TBM – Earth Pressure Balance (EPB)
Overburden thickness ranges:
Project conditions
10m – 30m
With a minimum value of:
3m – 4m
underneath sensitive buildings
(more than 2000 buildings in the influence zone)
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
A complex geologic ambient:
Weathered Granite
Metro do Porto. Geological Conditions
PortoWeathered Granite
Weathered “Granito do Porto“ exhibits a METASTABLE structure, which ,can accentuate a potential for collapse, depending on the high porosity and reduced cohesive strength of the loosed/leached residual soil.
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
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Metro do Porto. TBM - Geological Conditions
PortoWeathered Granite
Weathered “Granito do Porto“ exhibits a METASTABLE structure, which ,can accentuate a potential for collapse, depending on the high porosity and reduced cohesive strength of the loosed/leached residual soil.
The water table is located 10-25m above the tunnel, rarely following the shape of the surface topography.
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Metro do Porto. TBM - Geological Conditions
PortoWeathered Granite
Weathered “Granito do Porto“ exhibits a METASTABLE structure, whichWeathered Granito do Porto exhibits a METASTABLE structure, which can accentuate a potential for collapse, depending on the high porosity and reduced cohesive strength of the loosed/leached residual soil.
The water table is located 10-25m above the tunnel, rarely following the shape of the surface topography.
ADITIONALLY: a large number of old wells and “minas“ (old and small handmade water tunnels) with no register ) The vast number of these
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
handmade water tunnels), with no register...). The vast number of these elements have modified the hydro-geological characteristics of the ground; so, the water MOVES NOT ONLY IN THE POROUS MEDIUM AND FRACTURES, but ALSO ALONG THESE CHANNELS (MINAS...).
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Tunnels. TBM
TUNNELING BORING MACHINE
Selection Criteria
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Selection Criteria
Geology - Criteria for Selection of TBM (Babendererd et al 2004)
Rock Strength Rock Structure Water Ingress
Jointing Grain size
Unilat. compr.
MPa
cohesion Cu
KN/m²
Face Support
Shield Lining Install.
RQD Distance
< 0.02 mm
< 0.06 mm
Face Support
Shield Lining Install. Volumeper 30m³
Consequences on
> 250 - - - - 100 - 90 %
> 2 m - - unlimited pump capacity
250 90 2 0
Tunnels. Geology vs Tunneling Boring Machine
250
- 100
- behind
TBM
90- 75 %
2.0-
0.6 m - - behind TBM unlimited pump capacity
100
- 50
- behind
TBM
75 - 50 %
0.6 -
0.2 m - possible behind TBM > 20 l/s pump capacity
Rock 50 -
25 - recom.
behind TBM
50 - 25 %
0.2 -
0.06 m
possibly mech.
recom. in
TBM area
> 10 l/s face support
25 - 5
- recom. < 25 %< 0.06
m mech. required under shield > 5 l/s face support
5 - 1
recom. required under shield
< 25 %< 0.06
m
mech., possibly
EPB/Slurry required under shield > 2 l/s methodology
< 1 > 30 - required under shield
< 25 %< 0.06
m vary
mech., possibly
EPB/Slurryrequired under shield > 2 l/s methodology
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Soil 30 -
10 recom. required
under shield
> 30 % mech.,
possibly EPB/Slurry
required under shield > 2 l/s methodology
10 - 5
recom. required under shield
immed. grout.
> 20 % < 50 %EPB / Slurry
required
under shield immed. grout.
> 2 l/s methodology
5 - 1
required required
under shield immed. grout. > 10 % < 30 %
EPB / Slurry
required
under shield immed. grout.
> 2 l/s methodology
0
required required
under shieldimmed. grout. > 10 % < 20 %
EPB / Slurry
required
under shield immed. grout.
> 2 l/s methodology
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Metro do Porto. TBM - Design
Tunneling Design ApproachTBM Advance Plan
Due to the extreme variability, EPB‘s OPERATED IN CLOSED MODE.
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Tunnels. Geology vs Tunneling Boring Machine
GeologyWeathered Granite Different Cohesion Different Permeability !...
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
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Tunneling Design ApproachTBM Advance Plan
Due to extreme variability, the EPB‘s OPERATED IN CLOSED MODE.
Metro do Porto. TBM - Design
A special care to avoid any excessive displacements or subsidence due
to volume loss ahead, above and behind – implied a PAT (“Plan of
Advance of TBM“), which included, in adition to design information, a
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Tunneling Design ApproachTBM Advance Plan
Due to extreme variability, the EPB‘s OPERATED IN CLOSED MODE.
Metro do Porto. TBM - Design
A special care to avoid any excessive displacements or subsidence due
to volume loss ahead, above and behind – implied a PAT (“Plan of
Advance of TBM“), which included, in adition to design information, a
“report on the evaluation of the TBM working parameters“,
containing the definition of the reference value and the relevant
operational range for:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
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Tunneling Design ApproachTBM Advance Plan
Due to extreme variability, the EPB‘s OPERATED IN CLOSED MODE.
Metro do Porto. TBM - Design
A special care to avoid any excessive displacements or subsidence due
to volume loss ahead, above and behind – implied a PAT (“Plan of
Advance of TBM“), which included, in adition to design information, a
“report on the evaluation of the TBM working parameters“,
containing the definition of the reference value and the relevant
operational range for:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
- face support pressure;
- apparent density of the muck in the chamber;
- weight to be extracted a each ring;
- longitudinal grouting pressure and volume; and,
- aditional bentonite slurry injection volume and pressure.
Tunneling Design ApproachTBM Advance Plan
Due to extreme variability, the EPB‘s OPERATED IN CLOSED MODE.
Metro do Porto. TBM - Design
A special care to avoid any excessive displacements or subsidence due
to volume loss ahead, above and behind – implied a PAT (“Plan of
Advance of TBM“), which included, in adition to design information, a
“report on the evaluation of the TBM working parameters“,
containing the definition of the reference value and the relevant
operational range for:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
- face support pressure;
- apparent density of the muck in the chamber;
- weight to be extracted a each ring;
- longitudinal grouting pressure and volume; and,
- aditional bentonite slurry injection volume and pressure.
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Tunneling Design ApproachTBM Advance Plan
Due to extreme variability, the EPB‘s OPERATED IN CLOSED MODE.
Metro do Porto. TBM - Design
A special care to avoid any excessive displacements or subsidence due
to volume loss ahead, above and behind – implied a PAT (“Plan of
Advance of TBM“), which included, in adition to design information, a
“report on the evaluation of the TBM working parameters“,
containing the definition of the reference value and the relevant
operational range for:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
- face support pressure;
- apparent density of the muck in the chamber;
- weight to be extracted a each ring;
- longitudinal grouting pressure and volume; and,
- aditional bentonite slurry injection volume and pressure.
Tunneling Design ApproachTBM Advance Plan
Due to extreme variability, the EPB‘s OPERATED IN CLOSED MODE.
Metro do Porto. TBM - Design
A special care to avoid any excessive displacements or subsidence due
to volume loss ahead, above and behind – implied a PAT (“Plan of
Advance of TBM“), which included, in adition to design information, a
“report on the evaluation of the TBM working parameters“,
containing the definition of the reference value and the relevant
operational range for:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
- face support pressure;
- apparent density of the muck in the chamber;
- weight to be extracted a each ring;
- longitudinal grouting pressure and volume; and,
- aditional bentonite slurry injection volume and pressure.
25
Tunneling Design ApproachTBM Advance Plan
Due to extreme variability, the EPB‘s OPERATED IN CLOSED MODE.
Metro do Porto. TBM - Design
A special care to avoid any excessive displacements or subsidence due
to volume loss ahead, above and behind – implied a PAT (“Plan of
Advance of TBM“), which included, in adition to design information, a
“report on the evaluation of the TBM working parameters“,
containing the definition of the reference value and the relevant
operational range for:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
- face support pressure;
- apparent density of the muck in the chamber;
- weight to be extracted a each ring;
- longitudinal grouting pressure and volume; and,
- aditional bentonite slurry injection volume and pressure.
Tunnels. TBM – Earth Pressure Balance (EPB)
Cutter Head Diam.:
Injection of Conditioning Additives into Tool Gap
EPB Characteristics
Cutter Head Diam.:8.74 – 8.94m
Max. Tunneling Thrust Force:
70,613 kNMax. Cutterhead Thrust Force:
22,200 kNMax. Cutterhead Torque:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
12,900 kNBreakaway Torque:
15,000 kNTotal Installed Power:
Approx. 4 MW
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Tunnels. Criteria for selection of TBM
Selection of TBM
Type of Face Support: (1) Pressurized Slurry
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Tunnels. Criteria for selection of TBM
Selection of TBM
Type of Face Support: (2) Pressurized Earth Paste (EPB)
Fill
Additives
WeatheredGranite
Working Chamber
ScrewConveyer
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Pressure CellsCutter Head
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Tunnels. Criteria for selection of TBM
Range of Slurry- and EPB- TBM ApplicationConsidering Grain-size Distribution
80
90
100
[ % ]Ton Schluff Sand Kies Steine Blöcke
fein mittel grob fein mittel grob fein mittel grob
Slurry-TBM drives12
3
8
0
0,002 0,06 2 63 2000,006 0,02 0,2 0,63 6,3 20 100
10
20
30
40
50
60
70
1000
80
90
100
1. Lyon2. Hamburg3. Grauholztunnel4. Wesertunnel5. Zürich, Hermetschloo-Werdhölzli 6. Zürich, Thalwil7. Portland, Gravel Alluvium8. Wittenberg (polymer suspension)
54
6
7
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Grain-size [mm]
0
0,002 0,06 2 63 2000,006 0,02 0,2 0,63 6,3 20 100
10
20
30
40
50
60
70
1000
9. Essen, U-Bahn Los 32/33
EPB-TBM drives
10. Milano, Passante Ferroviario9
10 11. Metro Porto11
Tunnels. Criteria for selection of TBM
Slurry limitation
High content of fines < 0,06 mm
requires expensive separation process
EPB limitation
³
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
High permeability k > 10-³
requires intensive conditioning
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Tunnels. TBM – Earth Pressure Balance (EPB)
Monitoring of the EPB machine
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Tunnels. TBM – Earth Pressure Balance (EPB)
Control of Excavated Material(weight) ( g )
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Reaction procedure :
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Tunnels. TBM (EPB) - Emergency
In an emergency situation
Unpredictable situation occurs
Meanwhile:
The instructions are implemented O.K.?
The excavation proceeds
The responsible engineer is called
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Emergency Procedure
The foreman is called
Emergency Procedure
The supervisor and managerare advised
Tunnels. TBM (EPB) - Emergency
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Tunnels. TBM (EPB) – Failure!
Two Major Accidents !...
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
The second, in 12 Jan. 2001, was dramatic !...
A sink hole was induced after 30m of the passing of the face.
Tunnels. TBM (EPB) – Failure!
A house was swallowed andan old lady was killed !...
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F th bl t
Tunnels. TBM (EPB) – Solution
From the problem to the solution !
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
A. Cardoso (FEUP) S. Babendererde E. HoekP. Marinos (NTUA)
Panel Specialists
The special case of PortoRequirements for Closed Mode
Geological Risks
Tunnels. TBM (EPB) - Classical
Geological Risks
Weathered Granite in all stages with variable cohesionand variable permeability
Classical EPB- TBM Process Risks
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
- No sensitive control instrumentation
- Overcharge of TBM operator for decisions to adaptoperation procedure to changed ground conditions
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Classical EPB - TBM
Operation mode open modesemi open modeclosed mode not clearly defined
Criteria ?
Tunnels. TBM (EPB) - Classical
Muck extractionvia belt conveyor
Muck extractionvia screw conveyor
Criteria ?
Open mode? Closed mode?
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
O i P l Process steering by operator
Control instrumentation not sensitive enough to react on frequentchanges of geotechnical properties in heterogeneous geology.
Classical EPB - TBM
Tunnels. TBM (EPB) - Classical
Operation Panel Process steering by operatorwithout reliable automatism
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Tunnels. TBM (EPBm) - Face Support
and
(9+
2)
sure
s S
enso
rs:
(7+
2) a
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Ear
th P
ress
Tunnels. TBM (EPBm) - Face Support
Transfer of Support Pressure
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The following modifications were made to the configuration:
Tunnels. TBM (EPBm) - Modified
SPECIAL FEATURES OF EPBM
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
The following modifications were made to the configuration:
SET UP OF AN ACTIVE SECONDARY FACE SUPPORT (SFSS):
SPECIAL FEATURES OF EPBM
Tunnels. TBM (EPBm) - Modified
SET UP OF AN ACTIVE SECONDARY FACE SUPPORT (SFSS):
an automatic SYSTEM that pumps bentonite slurry into the excavation chamber, whenever the pressure drops below a preset value;
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
35
The following modifications were made to the configuration:
SET UP OF AN ACTIVE SECONDARY FACE SUPPORT (SFSS):
SPECIAL FEATURES OF EPBM
Tunnels. TBM (EPBm) - Modified
SET UP OF AN ACTIVE SECONDARY FACE SUPPORT (SFSS):
an automatic SYSTEM that pumps bentonite slurry into the excavation chamber, whenever the pressure drops below a preset value;
INSTALATION OF AN EMERGENCY DOUBLE PISTON PUMP (EDPP) AFTER THE SCREW CONVEY,
in order to deal with the liquid muck and uncontrollable
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
in order to deal with the liquid muck and uncontrollable support pressure oscillations;
The following modifications were made to the configuration:
SET UP OF AN ACTIVE SECONDARY FACE SUPPORT (SFSS):
SPECIAL FEATURES OF EPBM
Tunnels. TBM (EPBm) - Modified
SET UP OF AN ACTIVE SECONDARY FACE SUPPORT (SFSS):
an automatic SYSTEM that pumps bentonite slurry into the excavation chamber, whenever the pressure drops below apreset value;
INSTALATION OF AN EMERGENCY DOUBLE PISTON PUMP (EDPP) AFTER THE SCREW CONVEY,
in order to deal with the liquid muck and uncontrollable
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
in order to deal with the liquid muck and uncontrollable support pressure oscillations;
INSTALATION OF A SECOND BELT SCALE,
in order to cross-check results of the first scale; and
36
THREE AUTOMATIC ALARM SYSTEMS:
SIGNIFICANT ADJUSTMENTS TO THE DRIVING SOFTWARE
Tunnels. TBM (EPBm) - Modified
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
THREE AUTOMATIC ALARM SYSTEMS:
1. EXCEEDING THE EXTRACTED WEIGHT upper limit,
SIGNIFICANT ADJUSTMENTS TO THE DRIVING SOFWARE
Tunnels. TBM (EPBm) - Modified
pp ,
automatically stops the advance;
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
37
THREE AUTOMATIC ALARM SYSTEMS:
1. EXCEEDING THE EXTRACTED WEIGHT upper limit,
SIGNIFICANT ADJUSTMENTS TO THE DRIVING SOFWARE
Tunnels. TBM (EPBm) - Modified
pp ,
automatically stops the advance;
2. EXCEEDING THE FACE SUPPORT PRESSURE lower limit,
automatically switches on the SFSS;
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
THREE AUTOMATIC ALARM SYSTEMS:
1. EXCEEDING THE EXTRACTED WEIGHT upper limit,
SIGNIFICANT ADJUSTMENTS TO THE DRIVING SOFWARE
Tunnels. TBM (EPBm) - Modified
pp ,
automatically stops the advance;
2. EXCEEDING THE FACE SUPPORT PRESSURE lower limit,
automatically switches on the SFSS;
3. EXCEEDING THE APPARENT DENSITY OF THE MUCK lower limit; AND
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
limit; AND
38
THREE AUTOMATIC ALARM SYSTEMS:
1. EXCEEDING THE EXTRACTED WEIGHT upper limit,
SIGNIFICANT ADJUSTMENTS TO THE DRIVING SOFWARE
Tunnels. TBM (EPBm) - Modified
pp ,
automatically stops the advance;
2. EXCEEDING THE FACE SUPPORT PRESSURE lower limit,
automatically switches on the SFSS;
3. EXCEEDING THE APPARENT DENSITY OF THE MUCK lower limit; AND
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
limit; AND
CONTINUOUS ANALYSIS OF THE TBM PERFORMANCE
(REAL TIME and BACK-ANALYSIS)
the KEY POINT is the utilization of
The solution for Metro do Porto TBMAdditive Face Support System
Tunnels. TBM (EPBm) - Face Support
Sensitive crown areaprone to unintendedpressure drop
Additional slurryinjection system
Drops of predeterminedsupport pressure will beautomatically compensated
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
compensatedby slurry injection.
39
S spension
Tunnels. TBM (EPBm) - Face Support
The solution for Metro do Porto TBM - EPBMSecondary Face Support System (SFSS)
SuspensionContainer
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Pressure Control
Tunnels. TBM – Earth Pressure Balance (EPBm)
Modified operation of the EPBM machine with an Active Secondary Face Support System
d (
9+2)
es S
enso
rs:
(7+
2) a
nd
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Scheme from Babendererde, Cardoso, Hoek, Marinos, report to Metro do Porto, 2001E
arth
Pre
ssu
re
40
Tunnels. TBM – Earth Pressure Balance (EPBm)
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Porto EPBM
Tunnels. TBM – Earth Pressure Balance (EPBm)
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41
Tunnels. TBM – Earth Pressure Balance (EPBm)
Combined Tool Arrangement
Disks and Shave Bits
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Tunnels. TBM (EPBm) - Face Support
Control of the extracted muck weight
The TBM incorporates a conveyor belt system for the removal;
The Weight was measured by using TWO BELT SCALES
P d f 3 4% Proved an accuracy of 3-4%;
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42
Tunnels. TBM (EPBm) - Face Support
Control of the extracted muck weight
The TBM incorporates a conveyor belt system for the removal;
The Weight was measured by using TWO BELT SCALES
P d f 3 4% Proved an accuracy of 3-4%;
HOWEVER, to adjust the reference value and the operation
It was NECESSARY TO EXECUTE FREQUENT FACE MAPPING (under pressure by visualization) and to estimate the GROUND IN SITU DENSITY, at least every 15m (horizontal survey);
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Tunnels. TBM (EPBm) - Face Support
Control of the extracted muck weight
The TBM incorporates a conveyor belt system for the removal;
The Weight was measured by using TWO BELT SCALES
P d f 3 4% Proved an accuracy of 3-4%;
HOWEVER, to adjust the reference value and the operation
It was NECESSARY TO EXECUTE FREQUENT FACE MAPPING (under pressure by visualization) and to estimate the GROUND IN SITU DENSITY, at least every 15m (horizontal survey);
Also necessary to SUBSTRACT the weight of the
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Also, necessary to SUBSTRACT the weight of the
CONDITIONING AGENTS ADDED during excavation (average 20-30m3 of water with polymer) !
43
Tunnels. TBM (EPBm) - Face Support
Control of the extracted muck weight
The TBM incorporates a conveyor belt system for the removal;
The Weight was measured by using TWO BELT SCALES
P d f 3 4% Proved an accuracy of 3-4%;
HOWEVER, to adjust the reference value and the operation
It was NECESSARY TO EXECUTE FREQUENT FACE MAPPING (under pressure by visualization) and to estimate the GROUND IN SITU DENSITY, at least every 15m (horizontal survey);
Also necessary to SUBSTRACT the weight of the
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Also, necessary to SUBSTRACT the weight of the
CONDITIONING AGENTS ADDED during excavation (average 20-30m3 of water with polymer) !
ADITIONAL CONDITION: tunnel with very tight curves (R=200m) => the balances were not correctly loaded (<accuracy)
Tunnels. TBM (EPBm) - Face Support
Installation for Conditioning
injection
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Injection of Additives Foam generator
44
Tunnels. TBM (EPBm) - Face Support
Management of face support pressure
As important as the weight control, this PARAMOUNT factor was:
Assured by IMPOSING A yMINIMUM EFFECTIVE PRESSURE;
ie, the support pressure SHOULD BE TRANSMITTED from the bulkhead to the face VIA SOLID PARTICLE and NOT ONLY through the pore
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Natural Ground: Clay as Support Medium
ONLY through the pore pressure or compressed air.
Tunnels. TBM (EPBm) - Face Support
Management of face support pressure
As important as the weight control, this PARAMOUNT factor was:
Assured by IMPOSING A MINIMUM EFFECTIVE PRESSURE;
ie, the support pressure SHOULD BE TRANSMITTED from the bulkhead to the face VIA SOLID PARTICLE and NOT ONLY through the pore pressure or compressed air.
CONSEQUENCE:
CHAMBER MUST ALWAYS BE FULL OF “SOLID” MIXTURE with adequate density (around 14kN/m3)
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
As additional safety measure,
THE REFERENCE SUPPORT PRESSURE WAS DEFINED AND MEASURED AT THE TOP OF THE BULKHEAD (1m below the tunnel crown), so that the other pressures were higher
45
Tunnels. TBM (EPBm) - Face Support
Face with Gravel and Stones - Conditioning is required
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Tunnels. TBM (EPBm) - Face Support
Management of face support pressure (cont.)
measuring pressures at
The density of the muck was evaluated systematically by
Elements of Face
measuring pressures at different bulkhead heights (dividing the difference in pressure by the height between monitoring points).
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Even with all this management care
instantaneous density figures fluctuated significantly (apparent!!!)
Elements of Face Pressure
46
Tunnels. TBM (EPBm) - Face Support
Control of Support Pressure and extracted muck weight
d (
9+2)
Additives
Advance Force
Cutter HeadRotation
ScrewConveyorRotation
es S
enso
rs:
(7+
2) a
nd
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Pressure CellsPressurizedEarth Paste
Ear
th P
ress
ure
Tunnels. TBM (EPBm) - Face Support
Conditioning agents
Both polymer and foam have proved to work successfully!
POLYMERS couldn’t help to reduce the very high tool-wear rate…
FOAM greatly reduced the wear rate, BUT required more complex and smoother operation of the screw conveyor.
Excessive wear
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47
Tunnels. TBM (EPBm) - Face Support
Effects on Filtration of Different Conditioning Agents
Bentonite Slurry
96% water
Limitedfiltration
Pressurizedearth paste
Conditioned with:
96% water4% solids
Filter cakeof water
Deepfiltrationof slurry
Poresblockedby polymerbundle
Polymer Slurry
99,8% water0,2% pseudo solids
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Forcestransferredgrain to grain
High filtrationof air andwater
Foam
91% air8,8% water0,2% foaming agent(300-600 l air/m3 soil)
Tunnels. TBM (EPBm) - Face Support
Earth Paste Conditioned with Foam
Proper ConditioningEarth Paste when airdiffused after TBM stopp g diffused after TBM stop
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48
Face conditions and TBM parameters
Tunnels. TBM (EPBm) - Modified
Analysis of the TBM operational parameters allows the
d t ti f d diti ( i il l t il d illi
Thanks to frequent face surveys, it was possible to
detection of ground conditions (similarly to oil drilling or
geotechnical investigations campaigns – DPR...).
Combination of
CUTTER HEAD THRUST, ADVANCE SPEED and DISC WEAR
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
CALIBRATE THE INTERPRETATION PARAMETRICAL
ANSWER, to avoid systemathic survey of the face!
Thanks to frequent face surveys, it was possible to
Tunneling (TBM - EPBm)
2 Unitsworking simulta-neously
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49
TBM ADVANCE RATES AND PRODUCTION
Tunnels. TBM (EPBm) - Modified
It made possible to achieve very good results in
1. Average daily production: 5 rings = 7m;
2. Best day (06/02/2002): 13 rings = 18.2m;
3 B t k (7 13 O t b 2002) 56 i 78 4
TBM operated 24-24h in six-day week, one of which was used to execute
cutterhead maintenance under hyperbaric conditions, leading to:
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
3. Best week (7-13 October 2002): 56 rings = 78.4m;
4. Best month (August 2003): 180 rings = 252m.
VERY POSITIVE AND ABOVE THE USUAL STANDARD!
Tunnels. TBM (EPBm) – Starting trenches
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50
Tunneling (TBM - EPBm)
2 TBM
Working in
Working out
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Tunnels NATM
TUNNELS NATMTUNNELS NATM
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51
Tunnels NATM
Tunnel J
• 300 m long
C ti 30 2• Cross-section – 30 m2
• Average Cover – 18 m
• Relatively competent materials
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0.00
0.00 0.00
Tunnels NATM
Tunnel J
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52
Tunnels NATM
Tunnel J
• Final Lining - Shotcrete
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Tunnels NATM
Lapa Tunnel
Rehabilitation of na existent tunnel
- creation of a 50 cm thickness invert in the zone passing over tunnel J;
- contact injection along the entire tunnel in order to guarantee the contact between the support and the ground;
- lining recover by water under pressure and adding a thin shotcretemembrane reinforced with a wire mesh or total substitution of the existent lining;
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
g;
- Watertighness and drainage of the tunnel, collecting water in the leaking points.
53
Tunnels NATM
Lapa Tunnel
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Tunnels NATM
Lapa Tunnel
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54
Cut & Cover Excavations
CUT & COVER EXCAVATIONSCUT & COVER EXCAVATIONS
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Underground stations
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55
Cut & Cover Stations
24 Agosto Station
• Diaphagm walls
• Universal solution for the tender phase
• Enormous difficultiesfor the construction
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Cut & Cover Stations
24 Agosto Station
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Diaphagm Wall Underpinned Diaphagm Wall Berlin type Wall
56
Cut & Cover Stations
24 Agosto Station Longitudinal Section
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Cut & Cover Stations
24 Agosto Station Cross Section
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57
Cut & Cover Stations
24 Agosto Station Cross Section
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Cut & Cover Stations
Solutions With Piles
• The smaller dimension allowed to pass over different materialsmaterials
• New equipments have a great torque and can easily perforate W4 materials
• Initial concern with the water table position:
• Initial solutions were watertigh (in the walls)
• Drainage during construction
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
58
Cut & Cover Stations
Trindade Station
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Cut & Cover Stations
Aliados Station
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59
Cut & Cover Stations
Lima Station
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Cut & Cover Stations
S. Bento Station
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60
Cut & Cover Stations
Water table lowering during excavation
• Settlements due to water table lowering were reduced (historic cyclic and seasonal variations)(historic cyclic and seasonal variations)
• There was a significant gain in the soil stiffness and strength
• Working conditions were more favourable
• In any case, it was impossible to excavate without a bottom protection and guarantying that no water lowering would occur
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Cut & Cover Stations
Water table lowering during excavation
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61
Cut & Cover Stations
Sequential Excavation Method
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Marquês
Station
Cut & Cover Stations
Sequential Excavation Method
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Salgueiros
Station
62
Cut & Cover Stations
Sequential Excavation Method
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Bolhão
Station
Cut & Cover Stations
Sequential Excavation Method
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63
Cut & Cover Stations
Sequential Excavation MethodPhase 0 Phase 1
2,0m
2,0m
Phase 2
Phase 0
Phase 3
2,0m
Phase 4
Phase 1
Phase 2
Phase 3 till Final Phase
Surface preparation, watertable lowering and cap beamconstruction
Partial or total excavation ofthe first ring
Shotcrete of the first ring
Sucesive excavation of aringollowed by immediateshotcreting until reaching thebottom of the excavation
NF
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Last but one Phase Final Phase
H=
20m
Raio
Cut & Cover Stations
Sequential Excavation Method
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64
Cut & Cover Stations
Salgueiros Station
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Cut & Cover Stations
Salgueiros Station
R1.60
79.95
WP 14
WP 15 WP 16
WP 1
WP 2 WP 3
WP 4
R1.65
1.60
0
25
.40
38
.27
Primary lining Final lining
WP 10WP 11
WP 12
WP 13 WP 6
WP 5
WP 7
WP 8WP 9
Well Points
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
6.60
3.6
01
2.0
2
2.00
0.30
0.60
0.45
28.
09 0.60
2.4
5
65
Cut & Cover stations
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Cut & Cover stations
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66
Cut & Cover stations
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Cut & Cover stations
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67
Mining stations
MINING STATIONSMINING STATIONS
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Mining stations
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Lima Station Marquês Station
68
Mining stations
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Heroísmo Station Faria Guimarães station
Mining stations
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Bolhão station
69
Mining stations
• Drainage during construction
• Final design support is “Functionally watertight”
• Several excavation phases
• Excavation in soil – Lattice girder were adopted
• Excavation was performed generally under the protection of an umbrella formed by horizontal jet-grouting
• In Faria Guimarães face reinforcement was adopted
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p
Mining stations
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Mining stations
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Heroísmo Station
Mining stations
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Faria Guimarães Station
71
Mining stations
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Faria Guimarães Station
Mining stations
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Faria Guimarães Station
72
Mining stations
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Heroísmo station
Mining stations
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Heroísmo station
73
Mining stations
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Lima station sttion
Mining stations
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Lima station
74
Mining stations
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Lima station
Mining stations
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Lima station
75
Mining stations
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Marquês station
Mining stations
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Bolhão station
76
Mining stations
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Bolhão station
Mining stations
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Bolhão station
77
Mining stations
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Bolhão station
Mining stations
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Bolhão station
78
Mining stations
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Faria Guimarães station
Mining stations
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Faria Guimarães station
79
Mining stations
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Faria Guimarães station
Mining stations
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Faria Guimarães station
80
Mining stations
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Faria Guimarães station
Mining stations
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Faria Guimarães station
10 mm20 mm30 mm40 mm
81
Mining stations
Estação Lima Heroísmo
TBM information
Estação Lima Heroísmo
Section (m2) 62,8 62,8
Cover(m) 15 18
Maximum Settlment(mm)
9,3 8,1
Volume loss (%) 0,36 0,36
Inflexion point
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Inflexion point (m)
9,74 11,24
Mining stations
NATM excavations
Estação Heroísmo Marq êsEstação Heroísmo Marquês
Section (m2) 232 182
Cover(m) 13 18
Maximum Settlment(mm)
9,5 19,4
Volume loss (%) 0,32 0,49
Inflexion point
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Inflexion point (m)
14,7 18,2
82
Mining stations
NATM excavations
Distância ao eixo túnel (m)0
Ajuste de Gauss - Marquês
-10-20-30-40 10 20 30 40 50-500
5
10
sent
amen
to (
mm
)
010203040 10 20 30 40 5050
5
10
5
10
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15
20
Ass
Medições Ajuste
15
20
15
20
Mining stations
NATM excavationsRua de Faria Guimarães/Rua de Fonseca Cardoso - Lado Este
Perfil longitudinal de assentamentos (alvos automáticos)
5,0
1596A2.1
1597A2.1
1598A2.1
1599A1.1
1599A2.1
1601A1.1
1601A2.1
1603A1.1
1602A1.1
1602A2.1
1623A3.1
1624A1.1
1625A1.1
1625A2.1
1626A1.1
1628A1.1
1629A1.1
1629A2.1
1681A1.1
G l i C i
-35,0
-25,0
-15,0
-5,0
Ass
enta
men
to (
mm
)
Poço Fonseca Cardoso
Galeria Cais
PoçoFaria
Guimarães
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-65,0
-55,0
-45,0
04/02/04 16/02/04 01/03/04 16/03/04 29/03/04 12/04/04 29/04/04 17/05/0426/05/04 31/05/04 07/06/04 14/06/04 21/06/04 28/06/04 05/07/04 12/07/0419/07/04 26/07/04 02/08/04
83
Acknowledgments:
M t d P t d N t
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
Metro do Porto and Normetro;Prof. Luís Ribeiro e Sousa; Prof. Paul Marinos; Dr. Siegmund Babendererde.
OBRIGADO PELA VOSSA ATENÇÃO !
THANK YOU FOR YOUR ATTENTION !
Jornadas “TÚNELES Y EXCAVACIONES EN GRANITO” Abril 2010
António Viana da Fonseca & António Topa Gomes
@ FEUP 2010