Experimental study on face instability of shield tunnel in sand

Face stability is critical for ground settlement and construction safety control in shield tunneling. In this paper, a series of 3D large-scale model tests with a tunnel of 1 m diameter were conducted in dry sand for various cover-to-diameter ratios C/D = 0.5, 1, and 2 (i.e., relative depth; C is the cover depth and D is the diameter of tunnel). Each test provided a measurement of the support pressure and the ground settlement with the advance of face displacement. The evolution of soil arching during face failure was investigated by monitoring the redistribution of earth pressure in front of the face in the test case of C/D = 2. In the displacement-controlled face failure tests in the medium density sands, the support pressure dropped steeply to the minimum value, then increased to a steady state with the continuing increase in the face displacement. Relationships between the support pressure and face displacement for various cover depths were also verified by the numerical analysis using the finite difference program, FLAC^3D (Itasca, 2005). The limit support pressure increases with the increase of the relative depth C/D and then tends to be constant. A significant rotation of principal stress axes in the upward arches in the soil during face failure was found in the tests. A two-stage failure pattern is proposed based on the observation of earth pressure. The theoretical and empirical formulas for estimating limit support pressure were verified by the tests results.     

Characteristics and mechanisms of large deformation in the Zhegu mountain tunnel on the Sichuan–Tibet highway

The Zhegu mountain tunnel is a typical long, deep-buried highway tunnel at a high altitude, subjected to low temperatures and high geostress. The tunnel is excavated in carbon phyllite and slate at depths of up to 1000 m below ground, which has resulted in extreme deformation, especially in a depth of 3 m from the tunnel perimeter. The maximum deformation was monitored to be 60 cm, with a maximum deformation speed of 39.3 mm/day. In addition, it took 60–120 days to complete 90% of the deformation. The deformation of the Zhegu mountain tunnel is characterized by serious subsidence of the arch, squeezing outwards of sidewalls, buckling failure of sidewalls and local collapse. The swelling of soft rock is found not to be a main factor of large deformation in the subject tunnel. Three mechanisms of large deformation are derived based on the characteristics and geological conditions, which are plastic flow of soft rock, shear sliding of wedges, and bending of thin-layered soft rock.     

Sequential excavation,NATM and ADECO: What they have in common and how they differ

Rabcewicz, 1964, Rabcewicz, 1965 maintained that “tunnels should be driven full face whenever possible”. ADECO, which stands for “Analysis of Controlled Deformations in tunnels”, now allows us to fulfill Rabcewicz’s dream in any stress–strain condition. In order to achieve that dream and its consequent control over cost and schedule, however, NATM must be abandoned for the ADECO. The paper traces the history of the sequential excavation, NATM (as first conceived) and Analysis of Controlled Deformations (ADECO) with the aim of shedding light on the unavoidable use of sequential excavation in “soft ground”, and of highlighting advances in tunnel design and construction that have occurred in Europe after and as alternates to the NATM. The paper presents the basic concepts in the ADECO approach to design, construction and monitoring of tunnels together with some case histories, including: full face excavation for Cassia tunnel (face area > 230 m²) in sands and silts under 5 m cover below an archeological area in Rome, Italy; Tartaguille tunnel (face area > 140 m²) advanced full face in highly swelling and squeezing ground under 100 m cover where NATM led to catastrophic failure, France; and 80 km of tunnels (face area > 140 m²) advanced full face in highly squeezing/swelling ground under 500 m cover for the high-speed railway line between Bologne and Florence, Italy (turnkey contract).     

A new energy-absorbing bolt for rock support in high stress rock masses

An energy-absorbing rock support device, called a D bolt, has been recently developed to counteract both burst-prone and squeezing rock conditions that occur during underground excavation. The bolt is a smooth steel bar with a number of anchors along its length. The anchors are firmly fixed within a borehole using either cement grout or resin, while the smooth sections of the bolt between the anchors may freely deform in response to rock dilation. Failure of one section does not affect the reinforcement performance of the other sections. The bolt is designed to fully use both the strength and the deformation capacity of the bolt material along the entire length. The bolt has large load-bearing and deformation capacities. Static pull tests and dynamic drop tests show that the bolt length elongates by 14–20% at a load level equal to the strength of the bolt material, thereby absorbing a large amount of energy. The impact average load of a 20 mm D bolt is 200–230 kN, with only a small portion of the load transferred to the bolt plate. The cumulative dynamic energy absorption of the bolt is measured to be 47 kJ/m. D bolts were tested in three deep mines. Filed measurements show that D bolts are loaded less than rebar bolts. This paper presents the layout and principle of the D bolt, and corresponding results from static, dynamic, and field tests.     

Centrifuge modelling of tunnel face reinforcement using forepoling

This paper investigates the effect of forepoles on stability of tunnel face and unsupported length during tunnel excavation in clay beds. Forepoles were modelled using 1 mm diameter brass rods. The tests were conducted using 65 mm diameter model tunnels with a flexible face at 100g centrifuge environment. The unsupported length of the tunnel varied between 1 and 1.5 times the tunnel diameter in different tests. The results seem to suggest that forepoles influence to reduce the length of settlement trough ahead of the tunnel face. However, width of the settlement trough remained unaffected. Excess negative pore pressures after collapse were noted to decrease with distance ahead of the tunnel face and increase with depth from the surface up to the tunnel axis. However, scatter in the measured data points suggest that the tunnel stability depends not only on the unsupported length of the tunnel but also on the length of forepoles. It is difficult to include these effects in the simple plasticity solution framework wherein the soil structure interaction is ignored.     

Critical embedment length and bond strength of fully encapsulated rebar rockbolts

A series of rock bolt pull tests were carried out in the laboratory to determine the critical embedment length of a specific type of fully cement-grouted rebar bolt. The rebar bolt is 20 mm in diameter, and it is widely used in underground excavations in Norway. Three water-cement (w/c) ratios were used in the tests. It was discovered that the critical embedment length of the rock bolts was approximately 25 cm for the water-cement ratio 0.40 (the corresponding uniaxial compressive strength (UCS) of the grout is 37 MPa), 32 cm for the ratio 0.46 (UCS 32 MPa), and 36 cm for the ratio 0.50 (UCS 28 MPa), for the specific type of cement, Rescon zinc rock bolt cement. It was found that the bond strength of the rock bolt is not a constant but is related to the embedment length. The bond strength was linearly proportional to the UCS of the grout.     

Opening the excavation chamber of the large-diameter size slurry shield: A case study in Nanjing Yangtze River Tunnel in China

Shield tunnel construction in a dense strata often encounters malfunction of shield-tunneling machine or abrasion of cutters. Accessing to an excavation chamber under compressed air is a main method to repair and replace worn cutters. And many safety issues such as stability of the excavation face were involved. However, the face stability due to opening an excavation chamber was not fully studied. To overcome this shortcoming, face support scheme and stability analysis were presented in a case history of opening the pressure chamber for a large-diameter (up to 14.93 m) slurry shield tunnel constructed underneath Nanjing Yangtze River. Since most of the damaged cutters were distributed along the edge of cutting wheel, only top 3 m of tunnel face within the chamber needed to be supported by compressed air, and remaining area would also to be supported by slurry pressure. A series of simple primary laboratory tests were carried out to design an optimum slurries mixing scheme to support the tunnel face as accessing to the pressure chamber in the project. The face stability was analyzed in terms of the pressure equilibrium (i.e., internal and external pressures) as well as three-dimensional numerical analysis by adopting properties of soils and filter cakes from laboratory tests. By injecting lower density slurry into the sand to form a stable infiltration zone, followed by using higher density slurry to create a filter cake at tunnel face, compressed air-support system could ensure face stability during maintenance of cutter wheel. The success of applying the mixed slurry and compressed air-support scheme in this project is valuable to shield tunnel constructions in similar ground conditions.     

Performance of fully encapsulated rebar bolts and D-Bolts under combined pull-and-shear loading

The performance of two types of rock bolts, fully encapsulated rebar and D-Bolt, under combined pull and shear loading were studied in the laboratory. A new test approach was developed to apply the pull and shear loads to the rock bolt at the same time so that the bolt is displaced in a direction different from the bolt axis. Five displacing angles between 0° (pure pull) and 90° (pure shear) were employed in the tests. The test results show that the linear elastic stiffness of both the D-Bolt and the rebar bolt is mobilised quickly after a small displacement. When the displacing angle is larger than 40°, grout crushing may occur underneath the bolt shank, resulting in reduction in the stiffness of the bolt. The ultimate load of the bolts remains approximately constant no matter what the displacing angle is for both the D-Bolt and the rebar bolt. The displacement capacity of the D-Bolt, however, is dependent on the displacing angle. The ultimate displacement of a 1-m long D-Bolt section varies from 140 mm under pure pull (0°) to approximately 70 mm when the displacing angle is larger than 40°. The ultimate displacement of the rebar slightly increases from 29 mm under pure pull to 53 mm under pure shear. In general, the displacement capacity of the D-Bolt is larger than that of the rebar bolt. It is approximately 3.5 times the rebar under pure pull and 50% higher than rebar under pure shear. The test results show that the displacing angle of the bolt is larger than its loading angle, which is also confirmed by the analytical solutions.     

Application of ground penetrating radar in grouting evaluation for shield tunnel construction

Uniformity and quality of the grout behind the lining segments have a great influence on the long-term settlement in shield tunnel construction in soft soil areas. In order to evaluate the effectiveness of the grouting treatment before the tunnel operation, a nondestructive testing method using ground penetrating radar (GPR) was proposed to detect the grout thickness behind the lining segments of metro lines in Shanghai, China. GPR has shown to be a viable approach due to the facts that: (1) the detecting objects (concrete segments, grout and soil) were in the depth of one meter or less; (2) dielectric parameters of all the materials can be obtained from the laboratory; (3) the contrasts in the dielectric properties among these three materials were large enough; (4) only the boundary between the grout and the soil needed to be found since the concrete segments had a known even thickness of 0.35 m. Three GPR frequencies 250 MHz, 500 MHz and 1 GHz were used in the field tests in Shanghai Metro line 9. The results showed that the 250 MHz GPR had a low resolution while the 1 GHz GPR had a shallow detecting depth. Frequency at 500 MHz showed the most promising results. These tests results demonstrated that nondestructive geophysics techniques such as GPR detection can be used to mitigate the risks of long-term ground settlement, a critical issue of shield tunnel construction in soft soil areas such as Shanghai.     

Maximum surface settlement based classification of shallow tunnels in soft ground

Prediction of the maximum surface settlement due to shallow tunnelling in soft grounds is a valuable metrics in ensuring safe operations, particularly in urban areas. Although numerous researches have been devoted to this issue, due to the complexity and a large number of the effective parameters, no comprehensive solution to the problem is available. In this study, a shallow tunnel classification system (STCS), based on maximum settlement, is proposed. The STCS holds on the results of several tunnelling projects around the world. The classifier categorises a tunnel based on geometry, ground, and performance characteristics. A decision tree classification method, after training with 20 cases, was successful to predict the maximum settlement for 14 tunnelling projects. The maximum surface settlement predictions were in the form of assigning a class label to each tunnel. Four tunnel classes were defined as follow: (i) class A (maximum settlement < 9.9 mm), (ii) class “B” (10 ⩽ maximum settlement < 19.9 mm), (iii) class “C” (20 ⩽ maximum settlement < 29.9 mm), and (iv) class “D” (maximum settlement ⩾ 30 mm). The most explanatory independent variables were selected, by the STCS, as follow: tunnel depth, diameter, volume loss, and normalised volume loss. The proposed classification scheme can be employed as a decision making aid in settlement prediction/prevention in shallow tunnelling in soft grounds. The STCS is proposed as a supplemental tool to the observational methods, and it is not expected to be a stand-alone measure for settlement.     

Load transfer mechanism in pile group due to single tunnel advancement in stiff clay

Construction of tunnels in urban cities may induce excessive settlement and tilting of nearby existing pile foundations. Various studies reported in the literature have investigated the tunnel–soil–pile interaction by means of field monitoring, centrifuge and numerical modelling. However, the load transfer mechanism between piles in a group, the induced settlement and the tilting of a pile group due to tunnel advancement has not been investigated systematically and is not well understood. This study conducts three-dimensional, coupled-consolidation finite element analyses to investigate tunnelling effects on an existing 2 × 2 pile group. The construction of a 6 m diameter (D) tunnel in saturated stiff clay is simulated. Responses of the pile group located at a clear distance of 2.1 m (0.35D) from a tunnel constructed at three different cover-to-diameter-of-tunnel ratios (C/D) of 1.5, 2.5 and 3.5 are investigated. The computed results are compared to published data based on field monitoring. It is found that the most critical stage for settlement, tilting and induced bending moment of pile group due to tunnelling is when the tunnel face is close to the pile group rather than at the end of tunnel excavation. The depth of the tunnel relative to the pile group has a vital influence on the settlement, tilting of pile group and the load transfer mechanism between piles in pile group induced by tunnel excavation. Tunnelling near the mid-depth of the pile group (i.e. C/D = 1.5) induces the largest bending moment in the piles, but the settlement and tilting of the pile group are relatively small. Based on a settlement criterion, apparent loss of capacity of the pile group is 14% and 23% for tunnels constructed at depths of C/D = 1.5 and at both C/D = 2.5 and 3.5, respectively. The largest load redistribution between the front and rear piles in the group and the largest tilting of the pile cap towards the tunnel occurs when tunnel excavated at C/D = 2.5.     

Ceiling-jet thickness and vertical distribution along flat-ceilinged horizontal tunnel with natural ventilation

A series of fire tests was conducted in a 10.0 m (L) × 0.75 m (W) × 0.45 m (H) model tunnel with a rectangular cross section, and detailed measurements were taken of the temperature and velocity within a quasi-steady state fire-driven ceiling-jet running along the centre of a ceiling.The ceiling-jet thickness was defined as the distance from the tunnel ceiling to the point where the temperature and/or velocity dropped to half of their maximums. Correlations to represent the variation in the ceiling-jet thickness along the tunnel axis were developed with the aid of a theoretical approach. The coefficients included in these correlations were determined based on the experimental results obtained. It was found that the ceiling-jet thickness derived from the temperature was 1.17 times greater than that from the velocity in the tranquil flow region.In the tranquil region, both the velocity and temperature showed top-hat distributions, with a bulging shape from the apex of the distribution towards the tunnel floor. A cubic function and coordinate transformation were applied to develop empirical formulae for the temperature and velocity distributions, which were represented by the dimensionless distance from the tunnel ceiling and dimensionless temperature rise and/or velocity at a given distance from the fire source. The correlation developed for the temperature distribution was compared with the results of large- and full-scale tunnel experiments, which verified its applicability.     

Shaking table test on reinforcement effect of partial ground improvement for group-pile foundation and its numericalsimulation

In this paper, particular attention was paid to the seismic enhancement effect of group-pile foundation with partial ground improvement method that is used for existing pile foundations in practical engineering. A model test on a full system with a superstructure, a nine-pile foundation and a sandy ground was conducted with the shaking table test device. The model pile is made from aluminum and the model ground is made from Toyoura Sand. The shaking table test device is 120 cm in width and 160 cm in length. The maximum acceleration is 1 g and the maximum displacement is 5 cm. The maximum payload is 16 kN and the highest frequency is 10 Hz. The model ground is carefully prepared to obtain a ground with controllable unified density. Before the shaking table test, the pattern of the partial ground improvement for an existed group-pile foundation is carefully selected using numerical tests with a 3D elastoplastic static finite element analysis. In the analysis, the nonlinear behavior of ground and piles are described by the cyclic mobility model (Zhang et al., 2007) and the axial force dependent model (AFD model) proposed by Zhang and Kimura (2002) can take into consideration of axial-force dependency in the nonlinear moment–curvature relations. The applicability of the numerical analysis has been verified in previous works by comparing the numerical results with a real-scale field tests (Kosa et al., 1998). Based on the results from the numerical tests on seismic enhancement effect of group-pile foundation with ground improvement, an optimum pattern of partial ground improvement of an existing pile foundations has been picked out for shaking table test. A numerical analysis using the program DBLEAVES (Ye, 2007) is also conducted for the same optimum pattern for comparison purposes. The effectiveness of the partial ground improvement method has been proved by both the shaking table test and the numerical analysis.     

Velocity and temperature attenuation of a ceiling-jet along a horizontal tunnel with a flat ceiling and natural ventilation

A series of fire tests was conducted in a small-scale tunnel with dimensions of 10.0 m (L) × 0.75 m (W) × 0.45 m (H) and a rectangular cross-section. Detailed measurements of the velocity and temperature within a steady fire-driven ceiling-jet running along the centre of the ceiling were conducted.Referring to a theoretical derivation process described in the literature as a starting point, correlations representing the velocity and temperature attenuation along the tunnel axis were developed.The values of the coefficients included in the developed correlation for the velocity attenuation were measured using a particle image velocimetry system during the experiments conducted in the small-scale tunnel. The value of the Stanton number was determined by considering the ceiling-jet thickness, which was derived from the velocity distribution. The values of the coefficients included in the developed correlation for the temperature attenuation were also determined based on experimental results described in the literature, which were obtained in a large-scale tunnel constructed using good heat insulation properties.Through these correlations developed for the velocity and temperature attenuations along the tunnel axis, the variation in the Richardson number of the ceiling-jet based on the distance from the fire source position along the tunnel axis was examined, and the position where the ceiling-jet changed from a shooting flow to a tranquil flow was determined. The boundary positions between the shooting and tranquil flows were determined using correlations between the velocity and/or temperature attenuation, which were compared with the variation in the Richardson number along the tunnel axis to verify their appropriateness.     

Construction of a large-section long pedestrian underpass using pipe jacking in muddy silty clay: A case study

This paper presents a case study of constructing a large-section long pedestrian underpass using pipe jacking method in Nanjing, China. The underpass, having a width of 7 m and a height of 4.3 m, was jacked 94.5 m in muddy silty clay under a busy roadway with 6.2 m overburden soil, meanwhile it traverses above the existed shield metro tunnels with just 4.5 m from the underpass bottom to tunnel vault. This paper introduced the design and construction schemes of this project in detail. A pre-construction three dimensional numerical simulation was conducted to investigate the responses of the roadway and metro tunnels to pipe jacking construction. Based on the simulation results, the field monitoring program was proposed, and the tunnels deformation and ground settlement were constantly monitored. The field performances of the metro tunnels and roadway were analyzed according to the monitoring data. In the jacking process, the micro-underbreak method was adopted. In order to decrease the tunnels uplift and ground settlement, the actual volume of soil conveyed out from soil chamber to ground surface was kept 95–98% of theoretical soil volume cut by cutter head. In general, this project is completed successfully without taking any additional time and money-consuming deformation control measures. The ground traffic and underneath metro runs well during the whole construction process.     

Assessing the ability of rock masses to support block breakage at the TBM cutter face

In order for tunnel boring machines to efficiently cut or break rock, it is necessary that the block of rock in contact with the cutter be adequately supported by the surrounding rock mass. This support is provided by the interlocking of blocks and the friction of the surfaces. If blocks are inadequately supported or become free without breakage the result can be jamming at the TBM face. Such blocky ground conditions are typically assessed according to the spacing and orientation of discontinuities (including joints) within the rock mass, typically using a rock mass classification system. In laboratory tests on cuttability or abrasivity of rocks, test samples are typically supported securely in a frame or jig. Numerical models of rock breakage also assume boundary conditions in which the sample is completely supported. Therefore the applicability of the results from laboratory and numerical studies depends on the same degree of support of blocks in the ground. The conditions required to adequately support a block for breakage are investigated and related to rock mass parameters, in particular, the three-dimensional patterns of discontinuities. A rock mass can be capable of providing adequate support to a block of rock such that the cuttability is adequately described by conventional methods. However, there are some rock mass conditions where support of blocks is not well developed, potentially resulting in otherwise unexpected poor TBM progress or jamming of TBM with loose blocks. Three-dimensional discontinuity patterns can be assessed using stereographic methods or borehole (α–β) methods. It is proposed that problematic conditions may occur where: two or more oblique (α between 20° and 70°) discontinuity sets are present (and over-represented relative to a uniform distribution); one or more of these discontinuity sets are dipping into the opening (β = 180° ± 90°) and additional discontinuities (in sets or randomly oriented) are present to form complete tetrahedral wedge blocks.     

Resistance of flush endplate connections under tension and shear in fire

This paper presents an experimental and numerical study to the resistance of flush endplate connections in fire. Six transient fire tests were performed on two types of connections with flexible and stiff endplate. For each connection, three load combinations were tested and the test results were reported. The test shows that most connections failed within the range of 500 °C to 650 °C. Extreme bending deformation of the endplate and flexural deformation of the bolt were observed when the plate thickness was 8 mm. When the endplate thickness became 16 mm, deformations occurred to the column flange and the bolts as the endplate became thicker than the column flange. Connection fire resistances were found to decrease with increase of either tension or shear, but the connection deformations were similar regardless of the load combination within the range tested. The three-dimensional finite element simulations of the tests with flush endplate connections were conducted with general-purpose finite element program ABAQUS. The results obtained from analysis showed a good agreement with the experimental responses. Parametric study was performed to the connection failure mechanisms under an extensive range of load combinations of tension and shear in fire using the finite element model. Conclusions were drawn regarding the tension and shear interactive relationships for the two typical connections at different temperatures.     

Ground response of closely spaced twin tunnels constructed in heavily overconsolidated soils

As part of the City of Edmonton’s light rail transit expansion, twin 6.5 m diameter oval shaped tunnels were constructed using conventional tunnelling methods. The geology of the site consists predominately of a hard, fissured cohesive till unit. The tunnel face construction was sequenced as top header, bench and invert excavations. At its narrowest, the pillar separating the twin tunnels was less than 1.5 m across or 0.23 tunnel diameters. Typically, the minimum pillar spacing required to reduce the interaction between twin, side by side tunnels is one tunnel diameter. Because the tunnel construction was within an urban environment, there was considerable concern with ground loss and excessive surface settlements. This study demonstrates that within similar materials, a pillar width of 0.5 tunnel diameters sufficiently reduces the tunnel interactions and minimize the risk of damage to nearby structures.     

Key techniques for the largest curved pipe jacking roof to date: A case study of Gongbei tunnel

The Gongbei tunnel, as a part of the Zhuhai Connection highway and Hongkong-Zhuhai-Macao Bridge project, is currently being constructed in Zhuhai, China. To guarantee the tunnel traversing under the Gongbei Port, a combination technology of curved pipe jacking roof for ground support and ground freezing for waterproof is applied. This jacked pipe roof, comprised 36 steel pipe strings of 1620 mm diameter with 355–358 mm gap between adjacent strings, has been faced with various challenges for design and construction due to the site conditions of multiple soft soil and high underground water pressure. These challenges include risks of excessive soil deformation, possibility of path deviation, excessive jacking force, leaking of pipe joint and failure of jacking machine gasketed launch and reception devices. This paper provides an overview of this project, summarizes the most challenging aspects they faced and introduces the relevant techniques applied during construction.     

Study of surface subsidence above an underground opening using a trap door apparatus

Physical model simulations have been performed to determine the effects of underground opening configurations on surface subsidence under super-critical conditions. This paper indicates the importance of the main factors that control the extent of subsidence produced on the surface and determines the effects of geometry of underground openings on the angle of draw, the maximum subsidence and the volume of the subsidence trough. A trap door apparatus with the test area of 95 × 95 cm² has been fabricated to perform the scaled-down simulations of surface subsidence. Gravel is used to represent the overburden in order to exhibit a cohesionless frictional behavior. In plan view the excavation dimensions are sufficient to induce maximum possible subsidence. The findings can be used to evaluate the subsidence profile for tunnels and caverns in soft ground. The results show that the angle of draw and the maximum subsidence are controlled by the width (W), length (L), height (H) and depth (Z) of the underground openings. The angle of draw and maximum subsidence increase with increasing L/W ratio and tends to approach a limit when L/W equals 3. For the same L/W ratio and H/W ratio, increasing the Z/W ratio reduces the angle of draw and maximum subsidence. The volume of the subsidence trough increases with increasing H/W ratio and L/W ratio. The width of the subsidence trough can be represented by sets of empirical relations. The relation between opening depth and subsidence trough developed by Rankin (for cohesionless soils) is in good agreement with most physical model results for deep openings (Z/W = 2–4), while for Z/W = 1, the predicted trough width is less than the physical model simulation. The volume of the subsidence trough is largest for Z/W = 2.5 and for H/W = 0.6, and is about 60% of volume of the underlying opening.