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o. Prof. em. Dr.-Ing. Dr. h.c. mult. Bernhard Maidl is the former Chair of Construction Technology, Tunnelling and Construction Management at the Ruhr University, Bochum. Prof. Maidl is currently partner of MTC - Maidl Tunnelconsultants GmbH & Co. KG, Munich and Duisburg.
Dr. Ulrich Maidl is the managing director of MTC - Maidl Tunnelconsultants GmbH & Co. KG, Munich and Duisburg as well as an officially appointed and sworn expert in tunneling and microtunnelling.
Prof. Dr.-Ing. Markus Thewes holds the Chair of Tunnelling and Construction Management at the Ruhr University, Bochum and is active in national and international associations.
The authors VII
Foreword to the English edition IX
Foreword to the 3rd German edition X
Foreword to the 2nd German edition XI
Foreword to the 1st German edition XII
1 Introduction 1
1.1 General 1
1.2 Historical development 1
1.3 Terms and descriptions 4
2 Support methods and materials 9
2.1 General 9
2.2 Action of the support materials 9
2.2.1 Stiffness and deformability 10
2.2.2 Bond 11
2.2.3 Time of installation 11
2.3 Timbering 12
2.3.1 General 12
2.3.2 Frame set timbering 13
2.3.3 Trussed timbering 14
2.3.4 Shoring and lagging 14
2.4 Steel ribs 14
2.4.1 General 14
2.4.2 Profile forms 15
2.4.3 Examples of typical arch forms for large and small tunnels 15
2.4.4 Installation 16
2.5 Lattice beam elements 19
2.6 Advance support measures 21
2.6.1 Steel lagging sheets and plates 21
2.6.2 Spiles 23
2.6.3 Injection tubes 25
2.6.4 Pipe screens, grout screens, jet grout screens 25
2.6.5 Ground freezing 28
2.7 Rock bolts 29
2.7.1 General 29
2.7.2 Mode of action 29
2.7.3 Anchor length and spacing 32
2.7.4 Load-bearing behaviour 33
2.7.5 Anchor types 36
2.8 Concrete in tunnelling 45
2.8.1 General 45
2.8.2 Construction variants 45
2.8.2.1 Two-layer construction 46
2.8.2.2 Single-layer construction 46
2.8.3 Shotcrete 48
2.8.3.1 General 48
2.8.3.2 Process technology, equipment and handling 49
2.8.3.3 Mixing and recipes 60
2.8.3.4 Influence of materials technology and process technology 72
2.8.3.5 Quality criteria, material behaviour and calculation methods, quality control 87
2.8.3.6 Mechanisation of shotcrete technology 91
2.8.3.7 Steel fibre concrete 100
2.8.3.8 Working safety 106
2.8.4 Cast concrete 111
2.8.4.1 Formwork 111
2.8.4.2 Concreting 114
2.8.4.3 Reinforced or unreinforced concrete lining 115
2.8.4.4 Factors affecting crack formation 118
2.8.4.5 Disadvantages of nominal reinforcement 118
2.8.4.6 Stripping times 119
2.8.4.7 Filling of the crown gap 119
2.8.4.8 Joint details 120
2.8.4.9 Single-pass process, extruded concrete 120
2.8.4.10 After-treatment 123
2.8.5 Precast elements, cast segments 124
2.8.5.1 Steel segments 124
2.8.5.2 Cast steel segments 125
2.8.5.3 Cast iron segments 126
2.8.5.4 Reinforced concrete segments 127
2.8.5.5 Geometrical shapes and arrangement 130
2.8.5.6 Details of radial joints 131
2.8.5.7 Circumferential joint details 131
2.8.5.8 Fixing and sealing systems 132
2.8.5.9 Segment gaskets 133
2.8.5.10 Production of reinforced concrete segments 134
2.8.5.11 Installation of segment lining 135
2.8.6 Linings for sewer tunnels 136
2.8.7 Yielding elements 142
3 The classic methods and their further developments 145
3.1 General 145
3.2 Full-face excavation 147
3.3 Partial-face excavation 148
3.3.1 Bench excavation 148
3.3.2 The Belgian or underpinning tunnelling method 148
3.3.3 The German or remaining core tunnelling method 151
3.3.4 The Austrian or upraise tunnelling method 154
3.3.5 The New Austrian Tunnelling Method 155
3.3.6 The English tunnelling method 161
3.3.7 The Italian or packing tunnelling method 161
3.4 Classic shield drives 163
3.5 The classic tunnelling machines 164
4 Shotcrete tunnelling 167
4.1 General 167
4.2 Top heading process 168
4.2.1 Shotcrete tunnelling method 168
4.2.2 Underpinning method 168
4.2.3 Crown pilot heading with crown beam 170
4.2.4 Shotcrete tunnelling with longitudinal slots 173
4.3 Core tunnelling method with side headings 175
4.4 Special processes using shotcrete 176
4.4.1 Compressed air 176
4.4.2 Ground freezing, grouting 176
4.5 Shotcrete in mining 178
4.5.1 Tunnel support 178
4.5.2 Shaft insets 179
4.6 Outlook for further development 182
4.7 The new Italian tunnelling method (ADECCO-RS) 182
4.7.1 Theoretical model 183
4.7.2 Procedure through the example of the new line from Bologna – Florence 184
5 Drill and blast tunnelling 189
5.1 Historical development 189
5.2 Drilling 191
5.2.1 General 191
5.2.2 Drills 192
5.2.3 Drill bits 200
5.2.4 Wear 206
5.2.5 Performance 207
5.2.6 Costs 210
5.3 Blasting 211
5.3.1 General 211
5.3.2 Explosives in tunnelling 213
5.3.3 Detonators and detonation systems in tunnelling 215
5.3.4 Transport, storage and handling of explosives 221
5.3.5 Charge determination 228
5.3.6 The drilling and firing pattern 232
5.3.7 Charge loading 235
5.3.8 Time calculation 239
5.3.9 Blasting technology aspects 241
5.4 Mucking 243
5.4.1 General 243
5.4.2 Loading machines 244
5.4.3 Muck conveyance 251
5.4.4 Output of transport vehicles 260
5.4.5 Examples of transport chains 260
5.4.6 Further developments 265
5.5 Combination of drill and blast with mechanised tunnelling processes 265
5.5.1 Combinations with roadheaders 265
5.5.2 Combination with full-face machines 266
5.6 Effects of blasting on the surroundings 267
5.6.1 Vibration 267
5.6.2 Composition and effects of the blasting gas emissions 275
5.7 Mechanisation and Automation 278
5.7.1 General 278
5.7.2 Emphasis of mechanisation 279
5.7.3 Computer-assisted drill jumbos 280
5.7.4 Mucking and tunnel logistics 282
6 Mechanised tunnelling 285
6.1 General 285
6.2 Categories of tunnelling machines 285
6.3 Shield machines 286
6.3.1 Categories of shield machines 286
6.3.2 Basic principle, definition 287
6.3.3 Face without support 292
6.3.4 Face with mechanical support 292
6.3.5 Face under compressed air 293
6.3.6 Face with slurry support 294
6.3.6.1 Functional principle 295
6.3.6.2 Slurry shield 295
6.3.6.3 Thixshield 297
6.3.6.4 Hydroshield 297
6.3.6.5 Mixshield as a Hydroshield version 299
6.3.6.6 Hydrojetshield 300
6.3.6.7 Hydraulic soil transport 300
6.3.6.8 Soil separation in shield operation with hydraulic transport 302
6.3.7 Face with earth pressure support 306
6.3.7.1 Functional principle 306
6.3.7.2 Scope of application and soil conditioning process 307
6.3.7.3 Use of foam with earth pressure shields 310
6.3.8 Blade tunnelling and blade shields 311
6.3.9 The most important verification calculations 313
6.3.9.1 Calculation of face stability with slurry and earth pressure support 313
6.3.9.2 Calculation of safety against breakup and blowout 315
6.3.9.3 Calculation of thrust force 316
6.3.9.4 Determination of the air demand for compressed air support 320
6.4 Tunnel boring machines in hard rock 322
6.4.1 Categorisation of machines for use in hard rock 322
6.4.2 Basic principles 322
6.4.3 Boring system 327
6.4.4 Thrust and bracing system 328
6.4.5 Support system 332
6.4.6 Ventilation 335
6.4.7 The use of slurry and earth pressure shields in hard rock formations 336
6.5 Special processes: combinations of TBM drives with shotcrete tunnelling 338
6.5.1 Areas of application 338
6.5.2 Construction possibilities 339
6.5.3 Example 344
6.6 Roadheaders (TSM) and tunnel excavators 353
6.6.1 Basic principle of a roadheader 353
6.6.2 Rock excavation by a roadheader 355
6.6.3 Ventilation and dust control with a roadheader 359
6.6.4 Profile and directional control of roadheaders 359
6.6.5 Construction sequence using a roadheader 360
6.6.6 Additional equipment and variations of roadheaders 361
6.6.7 Criteria for the selection of a roadheader 362
6.6.8 Comparison of partial face and full face machines 362
6.6.9 Combination of full face and partial face machines 364
6.6.10 Contour cutting process 364
6.6.11 Tunnel excavators 364
6.7 Checking the tunnelling machine for suitability and acceptance based on a risk analysis 366
6.7.1 Strategy to contain risk 367
6.7.2 Basic design 367
6.7.3 Analysis of obstructions 368
6.7.4 Machine specification 369
6.7.5 Acceptance of the TBM 370
6.7.6 Shield handbook 371
6.7.7 Data checks, functional tests 372
6.7.8 Implementation of the strategy through the example of the Elbe Tunnel and the Lefortovo Tunnel 372
6.7.9 Recommendations for the future 378
7 The driving of small cross-sections 379
7.1 General 379
7.2 Manned processes 380
7.2.1 General 380
7.2.2 Pipe jacking 380
7.3 Unmanned processes 385
7.3.1 General 385
7.3.2 Non-steerable processes, or with limited control of direction 386
7.3.3 Guided processes 395
7.4 Shafts and jacking stations 400
7.4.1 Thrust shaft 400
7.4.2 Reception shaft 401
7.4.3 Main jacking station 401
7.4.4 Intermediate jacking stations 401
7.5 Support, product pipe 402
7.5.1 Loading during pipe jacking 402
7.5.2 Loading in operation 403
7.5.3 Insertion of the product pipe 407
8 Ventilation during the construction phase 409
8.1 General 409
8.2 Ventilation systems 411
8.2.1 Natural ventilation 411
8.2.2 Positive pressure ventilation 411
8.2.3 Extraction ventilation 412
8.2.4 Reversible ventilation 412
8.2.5 Combined ventilation. 413
8.2.6 Recirculation systems 413
8.3 Materials 414
8.3.1 Fans 414
8.3.2 Air ducts 415
8.3.3 Dedusters 416
8.4 Design and cost 417
8.5 Special ventilation systems 423
8.5.1 Ventilation for TBM drives 423
8.5.2 Ventilation of roadheader drives 425
8.5.3 Automatic ventilation 425
Bibliography 427
Index 443
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