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Trenchless Technology
Adopting Rectangular TBM for Tunnel & Pedestrian Subway Construction
Shanghai Tunnel Engineering Co. Pte Ltd
Innotech Forum on Geotechnology
The Machine
• EPBM with rectangular
geometry
• Commonly used for the
construction of underground
pedestrian subways and metro
lines
• Since 2015, more than 10 such
RTBM projects have been
completed
Innotech Forum on Geotechnology
Rectangular TBMs/PJMs can be used for the construction of road tunnels,
underground pedestrian subways, and even metro lines where the overburden
is relatively shallow.
Road Tunnel Pedestrian Subway Metro Line
Applications
Innotech Forum on Geotechnology
ECC Cutter(Auxiliary
Cutter)
Main Cutter
ECC Cutter Drive(Auxiliary Cutter
Drive)Main Drive
Screw Conveyor
Articulation Jacks Thrust Ring
U-Ring
Thrust Block
Thrust Jack Frame
Cradle
Tail ShieldFront Shield 2Front Shield 1
RTBM Components
Innotech Forum on Geotechnology
Pipe Jack vs
Thrust Boring
Innotech Forum on Geotechnology
RectangularPipe Jacking Machine (PJM)
Circular Earth Pressure Balance Machine
(EPBM)
RPJM vs EPBM Thrust Boring
Innotech Forum on Geotechnology
AspectComparison
Rectangular PJM Circular EPBM
Thrust / Jacking
Force
Added weight of segment + skin
friction-
Geometrical
propertiesSusceptible to warping deformation
Uniform stress distribution; better load
bearing capability
Precast Elements Monolithic Segments form up a ring
Waterproofing Gaskets Gaskets
Pipejacking Thrust Boring
Thrust
System
Thrust
System
Tunnel Lining Design
Innotech Forum on Geotechnology
AspectComparison
Rectangular PJM Circular EPBM
Machine Cost Relatively cheaper Cost more
Site Utilization Less demanding (20-30% of TBM) Relatively demanding (Large)
Settlement
ControlVery good (Overcut = Annulus)
Overcut + Shield Annulus +
Tail Skin Gap
Alignment Straight Curvature
Excavation Cycle
Time4 – 12 hours 1 – 4 hours
PJM Site Setup TBM Site Setup
Cost, Productivity, Safety, & Efficiency
Innotech Forum on Geotechnology
AspectComparison
Rectangular PJM/EPBM Circular PJM/EPBM
Tunnel Space
Utilization
More efficient use of space
Approximately 35% more dead space
and 30% more excavated material
Finishing Works MinimalAdditional backfilling works required,
intermediate first stage concrete
For the same tunnel internal clearance requirements (e.g. 2100mm by 2000mm):
Space Utilisation and Finishing Works
Innotech Forum on Geotechnology
AspectComparison
Rectangular PJM Circular TBM
Ground
Conditions
Not suitable for hard ground, mixed
ground, and bouldersAny type
Cutterhead
InterventionsDependent on machine size Normally possible
Cutter ChangeCutter change not required for short
tunnel drives
Must be designed to accommodate
cutter change
Tunnel AlignmentShort and straight, intermediate
jacking stations may be requiredCan be designed for most alignments
Overburden Generally shallow Deep
Technical Comparison
Innotech Forum on Geotechnology
AspectComparison
Rectangular PJM Circular TBM
Costs Lower Higher
Site setup Simple Complicated
Tunnel Alignment Short and straightCan be designed to any length and
suitable curvature
Tunnel space
utilizationEfficient Dead space present
GeologyIdeally soft homogeneous ground with
shallow overburdenAny
Design More considerations and constraintsVersatile in design to suit varying
conditions
In summary, the rectangular PJM as a method of construction will outshine the TBM
in projects where:
1. Soft, homogeneous ground with relatively shallow overburden
2. Short and straight alignment
3. Site space constraint
Summary
Innotech Forum on Geotechnology
Notable Projects
&
Innovations
Innotech Forum on Geotechnology
Funan UPL, Singapore UPL, Zheng Zhou KT3B, Hong Kong
Mac
hin
e U
sed
Co
ntr
act
Info
rmat
ion Underground Pedestrian Linkway
Tunnel length – 105mInternal dimension – 6.6 x 4.8mAdvance rate – 1.5m/dayOverburden – 4m to 6m
Underground Pedestrian LinkwayTunnel length – 183mInternal dimension – 9 x 6.1m &;Internal dimension – 6 x 3mAdvance rate – 1.5m/dayOverburden – 4m to 6m
Underground Pedestrian LinkwayTunnel length – 148mInternal dimension – 3.9 x 2.8mAdvance rate – 2.5m/dayOverburden – 6.6m to 9m
Soil
Co
nd
itio
ns
Predominantly marine clay Predominantly silt and silty clay Predominantly fill, colluvium & alluvium
Notable Projects
Innotech Forum on Geotechnology
Steel Segments
For large dimension rectangular tunnelling
projects, the use of reinforced concrete tunnel
segment linings might not be practical due to
its mass.
Steel segments can be fabricated off-site and
delivered to site for assembly and tunnel
construction.
Segment Tipping Frame
Segment Turning Device
Other Innovations
Innotech Forum on Geotechnology
Hong Kong
Projects
Innotech Forum on Geotechnology
The RTBM was launched from Shing
Kai Road, and then dismantled and
removed from the retrieval shaft at Choi
Hung Estate.
RTBM Parameters
Shield Type EPB
Excavation
Dimensions5020mm x 4020mm
Max Thrust Speed 50mm/min
Max Total Thrust
Force36000 kN
Total Power 518 kW
Rated Torque 1287 kNm
Segment Specifications
Segment Outer
Dimension
5000mm x
4000mm
Width 1500mm
Thickness 500mm/600mm
Design Life 120 Years
Design Strength 60 MPa
Segment Inner
Dimension4000mmx2900mm
Contract KT3B – Project Introduction
Kai Tak Development – Stage 3B
Infrastructure at Former North Apron
Area
Innotech Forum on Geotechnology
Challenges Description
Varying Ground
ConditionsVarying ground conditions along the planned tunnel alignment
Shallow OverburdenShallow overburden poses significant engineering challenges, especially in soft/fill
ground conditions
Under-crossing
Existing Structures &
Road
The tunnel alignment under-crosses Shing Kai Road, elevated Kwun Tong Bypass
expressway, 4-lane Prince Edward Road East, & an existing 4-cell box culvert
Under-crossing
Existing Underground
Utilities
The RTBM under-crosses many existing utilities such as the 400kV & 132kV power
cables, telecommunication lines, gas pipes, pipes for the district cooling system,
sewage pipes, drainage pipes, and water mains
Contract KT3B – Challenges
Innotech Forum on Geotechnology
Contract KT3B – Milestones & Activities
RTBM FAT Tunnel Construction RTBM Breakout
Replacement Grouting RTBM Disassembly Completion of Tunnel
Innotech Forum on Geotechnology
Advantages TBM Tunnelling
Productivity Approximately 30% increase in productivity
Engineering Safety Better control of soil movement and ground settlement
Construction Safety Workers physically shielded from the soil face
Quality Control Precast elements used
Environmental Control Lower noise/dust production
Diversion Works Significantly less traffic and utility diversion works
Contract KT3B – Advantages of RTBM
Innotech Forum on Geotechnology
Upcoming Project – KT5B
Construction of an underground pedestrian subway across PERE between Kai
Tak Area and Sa Po Road (Kowloon City).
Conforming Design(cast in-situ concrete lining)
Proposed Design (CSD)(realigned and constructed using RTBM)
Innotech Forum on Geotechnology
Upcoming Project – KT5B
Feasibility of Trenchless Excavation Method over Open-cut Method
• High traffic volume along PERE makes trenchless excavation method of construction more favourable for SB-01 construction
• Traffic diversion works can be avoided
• Utility diversion works can be avoided since RTBM will go underneath the existing utilities
• Lower impact to surrounding structures due to better settlement control
• Successful construction of KT3B underground subway on 02 Oct 2020 using the same method
Innotech Forum on Geotechnology
Upcoming Project – KT5B
RTBM and Segment Design RTBM Parameters
Shield Type EPB
Excavation
Dimensions
10830mm x
7530mm
Max Thrust Speed 40mm/min
Max Total Thrust
Force65000 kN
Total Power 1000 kW
Rated Torque 2500 kNm
Segment Specifications
Segment Outer
Dimension
10800mm x
7500mm
Width 1500mm
Thickness 700mm
Design Life 120 Years
Design Strength 60 MPa
Segment Inner
Dimension
9400mm x
6100mm
Innotech Forum on Geotechnology
RTBM Track
Records
Innotech Forum on Geotechnology
Year 1995 – First
Generation
2.5m × 2.5m Variable
Grid Rectangular
Shield
Year 1999 – Second
Generation
3.8m × 3.8m
Rectangular Shield
Equipped with
Cutterhead
Year 2003 – Third
Generation
4m × 6m Rectangular
Shield with Eccentric
Rotation Cutterhead
Year 2011 – Fourth
Generation
4.2m × 6.9m Rectangular
Shield with General and
Eccentric Rotation
Cutterhead
Year 2013 – Larger
Machine (4th Gen)
7.5m × 10.4m Rectangular
Shield with Combination of
Circular and Eccentric
Rotation Cutterhead
Year 2017 – Fourth
Generation
7.6m × 6.4m Rectangular
Shield with 9 nos. of multi-
layer cutterhead
Tim
elin
e
Tim
elin
e
Evolution of the RTBM
Innotech Forum on Geotechnology
7.5m x 10.4m `
6m x 9m
7.6m x 6.4m
4.2m x 6.9m
4m x 6m
2002
Kun Shan Underpass
1999 2004
3.8m x 3.8m Shanghai Sewer Shanghai Metro
1995
2.5m x 2.5m Shanghai Sewer
0
1995 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 On-going (Years)
2.5x2.5m Year 1995
3.8x3.8m Year 1999
Second Generation
Third Generation
4x6m Year 2003
TREND CHART OF RECTANGULAR TBM (From 1995 to Present)
First GenerationRectangular TBM
LEGEND
(Dimensions)
Square TBM
Fifth Generation
7.5x10.4m Year 2012
Fouth Generation
4.2x6.9m Year 2011
2005Ningbo Underpass
2003Shanghai Sewer
2009Shanghai Underpass
2007Shanghai Conduit
2006Shanghai Metro
2006Shanghai Metro
2008Shanghai Metro
2008Shanghai Metro
2008Shanghai Underpass
2008Shanghai Metro
2008Shanghai Metro
2009Nanjing Metro
2009Nanjing Metro
2010Nanjing Underpass
2010Nanjing Underpass
2010Shanghai Metro
2009Nanjing Metro
2011Wuhan Metro
2003Shanghai Sewer
2007Shanghai Metro
2007Shanghai Metro
2012Shanghai Underpass
2009Shanghai Metro
2010Zhejiang Underpass
2011Zhejiang Underpass
2012Shanghai Metro
2013Shanghai Metro
2013Zhenzhou Metro
2014Shanghai Metro
2014Nantong Metro
2014Ningbo Underpass
2016Zhengzhou Underpass
2015Shanghai Underpass
2002Shanghai Underpass
On-goingShanghai San Men Rd Underpass
On-goingShanghai Jin An Temple
On-goingSingapore Funan UPL
Summary
Total Rectangular Tunnel Projects: >40
Our Track Records
THANK YOU
Shanghai Tunnel Engineering Co. Pte Ltd
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