INTERNATIONAL SEMINAR ON

MASS RAPID TRANSIT SYSTEM(MRTS)( )4th‐5th November 2014

    REVIEW AND ASSESSMENT OF CHALLENGES  REVIEW AND ASSESSMENT OF CHALLENGES  G CO S C O  O  C A  G CO S C O  O  C A  DURING CONSTRUCTION OF CHENNAI DURING CONSTRUCTION OF CHENNAI 

METRO METRO 

CONTENTCONTENT

PROJECT DETAILS

PROJECT DESCRIPTION

GEOLOGICAL AND GEOTECHNICAL OVERVIEW

TUNNELLING PERFORMANCE (TBM ADVANCE/EXCAVATION)TUNNELLING PERFORMANCE (TBM ADVANCE/EXCAVATION)

TUNNELING THROUGH STATION

TUNNEL – STATION INTERFACE

CROSS PASSAGE SOIL TREATMENT

DESIGN AND CONSTRUCTION OF UNDERGROUND AND ASSOCIATED TUNNELS FOR UAA‐01 & UAA‐05 AND ASSOCIATED TUNNELS FOR UAA 01 & UAA 05 

OF CHENNAI METRO

CLIENT :CHENNAI METRO RAIL LTD

GENERAL CONSULTANT :EMBYEGENERAL CONSULTANT :EMBYE

CONTRACTOR :TRANSTONNELSTORY‐AFCONS JV

DESIGNER :PARSONS BRINCKERHOFF

SOURCE OF FUND :FUNDED BY JICA

Total Twin Tunnel Length : 17.5 KM

UAA UAA  0101UAA UAA ‐‐ 0505

UAA UAA ‐‐ 0101

Afcons Project

SITE LAYOUT OF THE PROJECT

AA 01UAA 01

UAA 05UAA 05

EPBM EPBM –– Main BodyMain Body

20# shove rams

Transportation of TBM From Port to Site

View of EOT at Washermanpet

Tail Skin Lowering for TBM 718 at Shenoy Nagar Station

Front & middle Shields ready for lowering into Shaft 

TBM AssemblyTBM Assembly

Trial of Muck Tilting Divice

VIEW OF 1ST TUNNEL ‐ SHENOY NAGAR STATION

View of Twin Tunnel

Casting shed & View of Commissioned Moulds 

Segment casting at casting Yard Segment casting at casting Yard 

View of Segment  stacking 

Cutter Head / Cutting ToolsCutter Head / Cutting Tools

Sample TBM Data RecordSample TBM Data Record

Types of reports/records

•TBM Steering & alignmentTBM Steering & alignment

•TBM Excavation volume control

•Tunnel grouting records

•Ring survey & orientation recordRing survey & orientation record

•Ring build record (steps, cracks, 

damage etc)

•TBM Operational Data recordp

Typical Soil Profile  Typical Soil Profile  ‐‐ Packages 05Packages 05

Typical Mixed Soil Profile  Typical Mixed Soil Profile  ‐‐ Packages 01Packages 01

GroundGround LevelLevel :: ++22..855855

RoofRoof TopTop levellevel :: --00..420420

ConcourseConcourse LevelLevel :: --66..420420

BaseBase SlabSlab LevelLevel :: --1414..135135

DD--WallWall TipTip levellevel :: --2424..600600

Mixed GroundMixed Ground

Typical Rock Soil Profile  Typical Rock Soil Profile  ‐‐ Packages 01Packages 01

Soil ProfileSoil Profile‐‐Mannadi StationMannadi Station

Project UAA 01

Soil ProfileSoil Profile‐‐ Chennai Central StationChennai Central Station

Project UAA 01

Core DetailsCore Details

Surface Constraints

Saint Andrew’s ChurchSHIFTING OF MONUMENT AT RIPPON

BUILDING AREA

High Court Mannadi

Surface Constraint Chennai Central

SHC Shaft

Surface Constraint Chennai Central

Surface Constraint ‐Egmore

Surface Constraint - Railway tracks on the stretch High Court –Chennai Central and geological Profile

Surface Constrain - Railway tracks on the stretch Chennai Central ‐Mayday Park Tunnel

View of  Locomotive ‐Mayday ParkView of  Locomotive  Mayday Park

Tunnelling beneath Coovam River

Under Coovam River

100%

TYPICAL   GEOLOGICAL   PROFILE    VARIATION

60%

80%

100%

age

W1 W2 W3 W4Expected

20%

40%

Perce

nt

0%

4842

.0133

4847

4862

.9

4880

4891

4903

4910.4

4915

4923

4934

4940

4951

4956

4967

4977

4992

Chainage

60%

80%

100%

entage

Actual Profile

0%

20%

40%

3 7 9 0 1 3 4 5 3 4 0 1 6 7 7 2

Perce

4842

.0133

4847

4862

.9

4880

4891

4903

4910.4

4915

4923

4934

4940

4951

4956

4967

4977

4992

Chainage W1‐Fresh Rock W2‐Slightly weathered  Rock 

W3‐M Weathered RockW4‐ Highly Weathered Rock

Geological Variation Results:Cutter Consumption & Frequency of Intervention

TBM retrieval in wet condition

CHENNAI CENTRAL (Overlapping of Two Corridor)(Overlapping of Two Corridor)

Retrieval Shaft  at SCC ‐Mayday Park Tunnel

Obstacles during Tunnel OperationObstacles during Tunnel Operation

Ground Level

CL

Red Zone O

raZon

Gr

Zone

 

L

TUNNEL A

ange ne

reen ZoneGreen Z

Orang

e Zo

ne

TUNNEL BA B

1.0 mt 1.0 mt

Bore well influence 1mt from Extrados of TunnelBore well influence 1mt from Extrados of TunnelBore well influence 1mt from Extrados of Tunnel Bore well influence 1mt from Extrados of Tunnel SegmentSegment

Obstacles during Tunnel OperationObstacles during Tunnel Operation

UAA 01

NO. OF EXISTING WELLS IN DIFFERENT ZONES: UAA01

UAA 01

Project

RED ZONE  (11.355 m. f T l

ORANGE ZONE (5.15 m. from RED 

GREEN ZONE    ( 4.5 m. from 

TOTAL R + O + G

Projectfrom Tunnel 

CL)

(5. 5 m. from RZONE)

( 4.5 m. fromORANGE ZONE)

G

Package 01 304 98 90 492g

Package 0561 24 60 145

Total 365 122 150 637Total 365 122 150 637

BUILDING CONDITION SURVEY

BUILDING CONDITION SURVEY

TUNNELLING PERFORMANCETUNNELLING PERFORMANCEThe TBMS are normally operated on a 24 hr basis, working 2 shifts per day.p yThe following main results have been achieved:

Average Daily Production:.12 ..Rings =16.8 mBest Day(09/02/2013): 39rings=54 6 mBest Day(09/02/2013): 39rings=54.6 mBest week(04/02/2013 to 09/02/2013): 139 rings=182 mBest Month ( Oct 2013): 525 rings= 735 m

We have achieved 39 Rings Boring in a day first time in the World

Considering that all the 5 TBMs have been operated in a very sensitive urban environment, almost always in closed mode, these results can be regarded as very positive and above the usual standard.

Heave pressure verification

3 50

4.00

4.50

5.00

2.00

2.50

3.00

3.50

ress

ures

(bar

)

0.50

1.00

1.50

Pr

Cohesive material0.00

0+22

00+

260

0+30

00+

340

0+38

00+

420

0+46

00+

500

0+54

00+

580

0+62

00+

660

0+70

00+

740

0+78

00+

820

0+86

00+

900

0+94

00+

980

1+02

01+

060

1+10

01+

140

1+18

01+

220

1+26

01+

300

1+34

01+

380

1+42

01+

460

1+50

01+

540

1+58

0

CHAINAGE

Cohesive material

Heave pressure (by Jancsez th.) Recommended Max. Pressure

Recommended EPB pressure and G t I j ti  P  Grout Injection Pressure 

3.00

2.00

2.50

ar)

1 00

1.50

Pres

sure

s (b

0.50

1.00

0.00

1+58

0

1+62

0

1+66

0

1+70

0

1+74

0

1+78

0

1+82

0

1+86

0

1+90

0

1+94

0

1+98

0

2+02

0

2+06

0

2+10

0

2+14

0

2+18

0

2+22

0

2+26

0

2+30

0

2+34

0

2+38

0

2+42

0

2+46

0

2+50

0

CHAINAGE

Recommended pressure Min.pressure Max.pressure Grout injection system

Earth Pressure Monitoring

1

1.5

2

2.5

3

Pressur

e (b

ar)

0

0.5

1

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Earth P

Ring No. Mannadi Station D'W ll C tti

High Court S i  AD'Wall Cutting Station Area

2.5

3

3.5

ure (b

ar)

0.5

1

1.5

2

Earth Pressu

00 200 400 600 800 1000 1200 1400 1600 1800 2000

Ring No. 

Typical Machining Parameters monitoring

20000

25000

30000

orce

Thrust Force(kN)

22.53

3.5

M

Cutting wheel Rotation (rpm)

0

5000

10000

15000

0 500 1000 1500 2000

Thru

st Fo

00.51

1.52

0 500 1000 1500 2000

RPM

0 500 1000 1500 2000

Ring No. 

0 500 1000 1500 2000

Ring No. 

Torque(MN.m) Advance Speed (mm/Min)

2

2.5

3

3.5

4

que

30

40

50

60

eed(

)mm/M

in.

0

0.5

1

1.5

2

Torq

0

10

20

0 500 1000 1500 2000

Adv

ance Spe

0 500 1000 1500 2000

Ring No. Ring No. 

Operation steps in Mechanized Tunneling Operation steps in Mechanized Tunneling 

Making Launching ShaftA bl   f TBM  i i  Sh fAssembly of TBM Initial DriveMuck Out

Receiving ShaftTunnel Break through Dissemble TBM 

BoringAssembly of LiningGroutingSegment Lining

Close of Launching shaft  upon Completion

Retrieval of TBM to GroundtClose of receiving shaft

Grouting

p p

Segment yardCasting of Segment

Type of TBMType of TBMEPBM‐Mixed Ground Type EPB‐Soft Ground Type

UAA 01Washermanpet to Chennai CentralM f t H k ht

UAA 05Shenoy Nagar to Thirumangalam

Manufacture‐Herrenknecht Manufacture‐Herrenknecht

UAA 01May day Park to Chennai 

EPB‐Rock/Mixed Face

May day Park to Chennai CentralManufacture‐Robbins

TBM ConfinementTBM Confinement

Breaking Out Through Confinement

UAA 01Mining Through D  Th h

Interface Tunnel  Interface Tunnel  ‐‐ StationStation

Mining Through Station Trag Through

UAA 01Mining Through Drag Through

Break In Break InBreak Out Break Out

Break In

UAA 05

Break Out

Mining Through h h reak 

hrou

gh

Mining Through Drag Through Drag Through Br Th

Break InBreak InBreak Out Break InBreak Out

TBM 717  Break In – Anna Nagar  TBM Break In Shenoy Nagar StationTBM 717  Break In  Anna Nagar Tower

TBM Break In‐ Shenoy Nagar Station

View of 1st Tunnel & TBM 718 ‐ Shenoy Nagar Station

Mining Through StationMining Through Station

Plan

Elevation

TBM Drag through

TBM TBM Break throughBreak through717

718711

711 710717710 711 710717710

Tunnel Boring Machine SpecificationTunnel Boring Machine Specification

TBM’s Cost of each TBM & backup equipment 33.5CrTBM total weight 290 TExcavation diameter 6.6 mExcavation diameter 6.6 mOverall length 9.7 mElectrical power 940 kW Left & right rotation speed Max 4.57 rpmRam advance speed Max. 80 mm/minRam jacks 32 #Ram jacks 32 #Total advance thrust force 42000 KNEarth pressure sensors 6 #

TreatmentTreatmentCross Passage Soil Cross Passage Soil TreatmentTreatment