. i DEPART] AENT OF ? j HE TRANSPORTATION 1 8.5 . A37 NÜV G bdO no dot- jo. UMTA-MA-06-0100-79-12 LfBH ARY TSC- 1 UMTA- L — 7Q-4H MECHANICAL TUNNELING IN SOLID ROCK by Werner Rutschmann Consulting Engineer ETH 34 Wald Strasse 8134 Adliswil Zurich, Switzerland MAY 1980 FINAL TRANSLATION DOCUMENT IS AVAILABLE TO THE PUBLIC THROUGH THE NATIONAL TECHNICAL I I LD, I SP R NG F E INFORMATION SE R V CE . VIRGINIA 22161 Prepared for U.S. DEPARTMENT OF TRANSPORTATION URBAN MASS TRANSPORTATION ADMINISTRATION OFFICE OF TECHNOLOGY DEVELOPMENT AND DEPLOYMENT Office of Rail and Construction Technology Washi ngton , DC 20590 . NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Govern- ment assumes no liability for its contents or use thereof NOTICE The United States Government does not endorse pro- ducts or manufacturers. Trade or manufacturers’ names appear herein solely because they are con- sidered essential to the object of this report. First published 1974 by VDI-Verlag, Düsseldorf, Federal Republic of Geraany, underneath the title: Mechanischer Tunnelvortrieb im Festgestein by Dipl. -Ing. Werner Rutschmann 0VDI-Verlag GmbH, Düsseldorf, Federal Republic of Germany, 1974 All rights reserved. No part of this publication may be reproduced in any form or by any means, including photocopying and recording, without the written per- mission of the copyright holder, application for which should be addressed to the VDI-Verlag GmbH; Verlagsbereich Bucher; Lizenzen/Nebenrechte; Graf Recke- permis Strasse 84; Postfach 1139; D—4 Düsseldorf, West Germany. Such written sion must also be obtained before any part of this publication is stored in a retrieval system of any nature. ; H B u,5. Dep1. o-f Titans 0^40.+ 1 0^^, Tta», s po r-fa+i’o^v C«s-'^«r^ 18 , sr p ,A17 2- fj )0T- Technical Report Documentation Page T3C' 1. Report No. 2. Government Accession No. 3. Recipient’s Cotolog No. l' ,«/i> UMTA-MA-06-0 100-79- 12 PB '«Ö- ix/ 0 /3 4. Title ond Subtitle 5. Report Dote May 1980 6. er fo i P rm g. 0 gon i 20 ti on Code MECHANICAL TUNNELING IN SOLID ROCK n r i DEPARThiEi'- C. V I 8. Performing Orgonizotion Report No. 7. Author^s) TRANSPOiiTATIOM 5 Werner Rutschmann DOT-TSC-UMTA-79-40. 9. Performing Organization Name ond Address WiTT^ IMT 10. Work Umt No, (TRAIS) *Werner Rutschmann UM948/R9745 Consulting Engineer ETH I 11. Controct Grant LIBRARY or No. 34 Waldistrasse DOT-TSC-1281 8134 Adliswil; Zurich, ' Switzerland 13. Type of Report ond Period Covered 12. Sponsoring Agency Nome and Address U.S. Department of Transportation Final Translation 16.Urban Mass Transportation Administration Office of Technology Development and Deployment 14. Sponsoring Agency Code Office of Rail and Construction Technology Washington DC 2Q59Q UTD-30 15. Supplementary Notes Dr. Keith H. Morehouse Professor Herbert Einstein, MIT -'Translated by; Raytheon Service Co. Cambridge MA 02139 Cambridge, MA 02142 and Richard Robbins, The Robbins Co. Seattle WA 98108 Abstract This report is a complete translation of the German book "Mechanischer Tunnelvortrieb im Festgestein". It is an introduction to the principles of mechanized tunneling and provides detailed guidelines for practical application. The subject is introduced with a detailed review of technical aspects and terms relating to mechanized tunneling. This is followed by a discussion of the mechanics of rock cutting and implications on machine performance. Two related issues, the stability of underground openings and rock mass classification for tunneling are then presented; this serves the purpose of familiarizing the reader with aspects other than rock cutting that affect machine tunneling. All this forms the basis for a compre- hensive17, description of the entire mechanized18. tunneling system and its operation. Finally, recommendations for bid preparation and project execution are given, followed by a discussion of application limits. 19. 20. Key Words Distribution Statement Tunnel Boring Machines, Mechanical DOCUMENT IS Tunneling, Rock, A VAI CABLE TO THE PUBLIC Tunne ling THROUGH THE NATIONAL TECHNICAL INFORMATION SERVICE, SPRINGFIELD VIRGINIA 22161 Security Clossif. (of this report) Security Clossif, (of this page) 21. No. of P ages 22. Price Unclassified Unclassified 246 (8-72) Fotm DOT F 1700.7 Reproduction of completed poge authorized . author's foreword Machine tunneling, which according to reliable sources was done for the first time in the U.S.A. in 1856, and which was used successfully from 1881 to 1883 for the boring of two experimental tunnels for the English channel tunnel project, is a tunneling process which has gained increasing importance ever since the 1950's. Originating in the U.S.A. where it was used with spectac- ular success, mechanical tunnel cutting (or boring) has since been used on other continents and in other countries. Today, the greatest density of tunnel boring machines by any standard can be found in Europe. Although initially it was only used in low-strength sediments, mechanical tunnel boring machines today also cut high-strength and abrasive organic rock with technical as well as with economical success. Apart from a great number of successful tunneling projects which total several hundred kilometers, failures have also been recorded. Only in a few cases these could be attributed to the boring machines that were used. More often, the drive system was insufficient, or the condition of the rock required the withdrawal of a tunnel boring machine which was only designed for solid rock, or the management of the tunneling project did not acknowledge the special requirements of tunnel boring. These failures, wh ich for the most part could have been avoided, a s well as the fact that in journals and on occasion of tunneling symposiums on ly partial aspects of mechanical tunnel boring wer e dealt with, and that a complete presentation has been unavailabl e so far, hav e motivated the author to try to describe the proces s from all it s aspects. According to developmental trends, th e emphasis of the presentation lies on mechanical tunnel bor ing in medium and high-strength as well as in abrasive rock, and thus on full face excavation of radially symmetric cross sections This document is intended for construction managers, design and project engineers, as well as for students. The reader will find that mechanical tunnel boring is not the magic answer for tunnel building. However, he should also arrive at the conclusion that with critical planning and a project-oriented design of boring machines and systems as well as with a highly qualified work team and supervisory personnel, tunnels can be constructed within a wide range of geological conditions. These projects can be technically and economically more successful and can be constructed with more safety and speed than ever before. The author wants to express appreciation for: - the permission to visit the construction sites of numerous construction companies in Europe, North America and Africa. i i i . - the good contacts - in part existing for fourteen years: the manufacturers and representatives of the tunneling machine companies Atlas Copco Cp^’eviously Habegger) , Calweld, Demag, Dresser, Jarva, Lawrence, Robbins, and Wirth - the permission to publish research material of the Gotthard basis tunnel project: Dipl.-Ing. M. Portmann, director of the construction service of the Swiss Federal Railways. - the proofreading of the manuscript or parts thereof by Dipl.-Ing. W. Diethelm, Dipl.-Ing. A. Hurter, Dipl.-Ing. M.A. Borel and Dr.-Ing. M.A. Gaillard. Adi iswil/ Zur ich , May 1974 Werner Rutschmann Author IV , . , , - TRANSLATOR'S FOREWORD The widespread use of mechanized tunnel excavation has brought with it publication of many case histories and a variety of research reports and papers. Still missing so far was a textbook or similar publication that introduces principles and basic practical issues and that provides the tunnel designer and project manager with a guideline on how to consider mechanized tunneling. This gap has, to a large extent, been closed by the book " Mechanischer Tunnelvortrieb i n Fes tgestein" , which has been completely translated and Ts^ - - - presented as this Report No. UMTA-MA- 0 6 0100 79 1 2 . The author, Werner Rutschmann,* a tunnel designer and project manager with over 30 years of experience, has been involved in modern mechanized tunneling since its beginning. During the course of his work he not only became a leading expert in the area, reflected by his many consulting jobs involving tunnel boring machine application, but he also became con- vinced that the tunnel engineer needs to tailor his design to the excavation methods shown herein and thus should be familiar with machined tunnels. As indicated in Rutschmann's foreword, the book attempts to satisfy this objective and to serve also as an educational tool for civil and mining engineering students. The book was originally written in German and published by VDI Publishing House, Düsseldorf, in 1974 (VDI, Verein Deutscher Ingenieure, the German Engineering Society) . Richard Robbins who was aware of the book's existence and who saw the necessity of providing the tunnel design profession and newcomers to mechanized tunneling with a solid background, suggested its translation to the U.S. Department of Transportation. Russel MacFarland favorably responded to this idea and initiated negotiations with the author and publisher. Both generously agre ed to have the b ook translated for the b ene fit of the t unn e ling pr of e ssion to have a limi ted is s ue of 200 copies publ ished an d s old through NTIS, an d to f o re go any compensa t ion . Th e t ran s lat i on was performe d by Dr Kei th H .