For official Use Only

GOVERNMENT OF INDIA
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MINISTRY OF RAILWAYS
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Guidelines for
Design & Construction of Tunnels

fjiksVZ la- RDSO/2012/GE:G-0017

June 2012

Geo-technical Engineering Directorate

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Research Designs & Standards Organisation
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Lucknow – 226011
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 INDEX

SL Particulars Page

1. Preface 1

2. Chapter 1: Geo-Technical Investigations 2

3. Chapter 2: Choice of Tunnel system, Alignment & Shape/Size 21

of cross-section
4. CHAPTER 3: Tunnel excavation methods 25

5. Chapter 4: Tunneling Methods 31

6. Chapter 5: NATM 50

7. Chapter 6: Tunnel Design Methods 55

8. Chapter 7: Structural Design 72

9. Chapter 8: Instrumentation & Monitoring 90

10. Chapter 9: Drainage 96

11. Chapter 10: Ventilation, lighting & Fire safety 97

12. Chapter 11: Tunnel Survey 99

13. Chapter 12: Problems in Tunnelling 101

 Preface

Tunneling projects have always remained a challenge for engineers owing

to the unpredictable behavior of the ground strata. In spite of carrying out
elaborate geotechnical investigations to evolve the design of a tunnel and to
decide the appropriate tunneling methodology, unforeseen situations are often
encountered during execution.

Following factors in particular differentiate Tunnels from above ground

structures:
1. Unpredictability/variability of Ground- the principal construction
material.
2. The magnitude of the loads is basically unknown and as such, has to be
assumed considering various geological/geophysical investigations etc.
3. Impossibility of calculating a reliable factor of safety of tunnel
construction due to unpredictability/variability of both the
construction material and the loads.

As such Tunneling is a highly specialized field requiring a blend of

technical knowledge, field experience and engineering judgment.
Indian Railways (IR) is presently undertaking some highly challenging
construction projects in hilly terrains involving construction of tunnels under
difficult conditions. Presently there are no Indian Railways guidelines available
on Design and Construction of tunnels. Railway Board vide its letter dated
21.12.2011 advised RDSO to prepare Manual/Guidelines on design,
construction& maintenance of Tunnels. Considering the importance of the
subject, Geotechnical Engineering Directorate took up formulation of these
guidelines on top priority. The provisions of this guideline are based on
experience gained during field visits & extensive literature survey. For further
details a list of various code/manual/books/web links are given in reference
section.

Draft Guidelines on “Design and Construction of Tunnels” were

circulated to Zonal Railways for their comments / suggestions and final
guidelines are now being issued after obtaining Railway Board
(Railway Board letter no: 2011/CE-I/Tunnel, dated 26.07.2012).

1
The guidelines cover the key components of a tunneling project including
Geotechnical investigation, Design Philosophy, Construction methodology. It is
expected that these guidelines will enable engineers on Indian Railways to
develop a basic appreciation for complexity of Tunneling project and help them
in supervising tunneling projects being executed by Professional agencies.

Following Officials of Geotechnical Engineering Directorate of RDSO were

associated with the preparation of the Guidelines.

1. Shri Shirish Kesarwani, ED/GE

2. Shri P. Funkwal, ED/Structure
3. Shri Sanjay Mishra, Dir/GE
4. Shri P. K. Verma, ARE/GE
5. Shri Shiv Kumar, SSRE/GE.
6. Shri S. K. Gupta, SSRE/GE
7. Shri Anil Ram, JRE/GE

Inputs from Zonal Railways in form of feedback/comments, field

checklists, sample proformas, approved cross sections and designs would help
in further improving the guidelines.

(Shirish Kesarwani)
Executive Director/Geotechnical Engineering

2/1
 Chapter 1: Geo-Technical Investigations

1.0 General:

Successful planning, design and construction of a tunneling project requires

various types of investigative techniques to obtain a broad spectrum of
pertinent topographic, geologic, subsurface, geo-hydrological, and structure
information and data.

A geotechnical investigation program for a tunnel project must use

appropriate means and methods to obtain necessary characteristics and
properties as basis for planning, design and construction of the tunnel and
related underground facilities, to identify the potential construction risks, and
to establish realistic cost estimate and schedule.

Exploration programs for tunneling must be planned by construction

engineers in close cooperation with engineering geologists or geotechnical
engineers & designers.

2.0 Phases of Geo-technical Investigation Program

It is more efficient to perform geotechnical investigations in phases to focus

the efforts in the areas and depths that matter. Due to factors like high cost,
lengthy duration and limited access, it is recommended that investigations be
carried out in several phases to obtain the information necessary at each
stage of the project in a more cost-efficient manner.

The Preliminary investigations for planning and feasibility studies can

be confined to information studies (involving Collection, organization & study
of available data) and preliminary reconnaissance. Carrying out of Geological
mapping and minimum subsurface investigations at this stage would help in
comparing alternative alignments and for arriving at a conceptual preliminary
design.

More detailed geotechnical investigation need to be carried out during

Preconstruction Planning and Engineering Phase to refine the tunnel
alignment and profile once the general corridor is selected, and to provide
the detailed information needed for design. As the final design progresses,
additional geo-technical investigations might be required for fuller coverage
of the final alignment and for selected shaft and portal locations.

Geo-technical Investigations are also required to be conducted during

Construction phase for various purposes including confirmation of design
assumptions, obtaining forewarning of unfavorable tunneling conditions etc.

2
Figure below illustrates the flow process of the different phases of investigations:

Different phases of Geo-technical investigations are briefly described below:

2.1 Preliminary Geo-technical investigations for Feasibility Studies:

In this phase, the emphasis is on defining the regional geology and the basic
issues of design and construction.

This phase of Geo-technical investigations is conducted in two stages:

a) Collection, organization & study of available data

b) Preliminary survey

These stages are briefly described below:-

a)Collection, organization & study of available data:

Preliminary Geo-technical investigations for a tunnel project starts with

collection and review of available information to develop an overall
understanding of the site conditions and constraints at little cost.

Some possible sources of available information are:

(1) Topographical maps of Survey of India

(2) Geological maps & reports of GSI

3
 (3) Geological maps and reports from agencies other than GSI
(4) Geo-technical investigation reports from other agencies
(5) Case histories of other underground works in the region
(6) Details of land ownership (Government, Private, Forest), Access
routes, environmental sensitivity from State Govt./Local bodies
(7) Satellite images and aerial photographs from public or private sources

Existing data can help identify existing conditions and features that may
impact the design and construction of the proposed tunnel, and can guide in
planning the scope and details of the subsurface investigation program to
address these issues.

Published topographical, hydrological, geological, geotechnical,

environmental, and other information should be collected, organized and
evaluated.

In areas where seismic condition may govern or influence the project,

historical seismic records are used to assess earthquake hazards.

Records of landslides caused by earthquakes, documented by the other

agencies, can be useful to avoid locating tunnel portals and shafts at these
potentially unstable areas.

b) Preliminary survey:

The information studies as above should be followed by a preliminary survey

for concept development and preliminary design. Initial on-site studies
should start with a careful reconnaissance over the tunnel alignment, paying
particular attention to the potential portal and shaft locations. Features
identified on maps and aerial photographs should be verified. Rock outcrops,
often exposed in highway and railway cuts, provide a source of information
about rock mass fracturing and bedding and the location of rock type
boundaries, faults, and other geologic features. Features identified during
the site reconnaissance should be photographed & documented.

The reconnaissance should cover the immediate project vicinity, as well as a

larger regional area so that regional geologic, hydrologic and seismic
influences can be accounted for. A preliminary horizontal and vertical control
survey may be required to obtain general site data for route selection and for
design. This survey should be expanded from existing records, alignment
posts & benchmarks that are based on the same horizontal and vertical
datum that will be used for final design of the structures. Additional
alignment posts and benchmarks can be established, as needed, to support
field investigations and mapping.

Carrying out of following investigations at this stage is recommended to help

in comparing alternative alignments and for arriving at a conceptual
preliminary design:

4
  Preliminary Geological field mapping: with particular attention to
features that could signify difficulties like Slides (particularly in portal
areas), Major faults, thrusts etc. The mapping should identify major
components of the stratigraphy and the geologic structure, which form
the framework for zonation of the alignment and for the planning of the
explorations.

 Selected exploratory borings in critical locations

 Geophysical explorations if appropriate: Geophysical methods of

exploration are often useful at the earlier stages of a project because
they are relatively inexpensive and can cover relatively large volumes of
geologic material in a short time. The most commonly used techniques
are Seismic Refraction Survey and Electric Resistivity Survey.

Seismic Refraction Survey

Electric Resistivity Survey Results

 Aerial photography: to supplement existing data.

 Hydrological survey: to define the groundwater regime, aquifers,

sources of water etc.

As a part of the hydro geological survey, all existing water wells in the
area should be located, their history and condition assessed, and

5
 groundwater levels taken. Mapping of permanent or ephemeral streams
and other water bodies and the flows and levels in these bodies at various
times of the year is usually required.

Additional hydro geological work to be carried out at a later stage includes

measurements of groundwater levels or pressures in boreholes,
permeability testing using packers in boreholes, and sometimes pumping
tests.

2.2 Detailed Geo-technical investigations for Preconstruction Planning

and Engineering

This phase involves:

a) Conducting of investigations to finalize / refine the tunnel alignment and

profile once the alternative alignments within the general corridor have
been selected during Feasibility Study stage.

b) To provide the detailed information needed for design of tunnel &

selection of appropriate tunneling methodology.

Investigations carried out during this phase are:-

i) Topographical Surveys
ii) Subsurface Investigations
iii) Detailed Geological Mapping
iv) Detailed Hydrological survey & Groundwater
investigation
iv) Structure & utility preconstruction survey

These are briefly described below:-

i) Topographical Surveys:

Detailed topographic maps, plans and profiles are developed to establish

primary control for final design and construction based on a high order
horizontal and vertical control field survey.

The tunnel centerline should be finalized & incorporated into the contract
drawings of the tunnel contract, and all tunnel control should be based on
this centerline. During construction, survey work is necessary for transfer of
line and grade from surface to tunnel control points.

Accurate topographic mapping is also required to support surface geology

mapping and the layout of exploratory borings.

The principal survey techniques include:

 Conventional Survey
 Global Positioning System (GPS)

6
  Electronic Distance Measuring (EDM) with Total Stations
 Remote Sensing
 Laser Scanning

ii) Subsurface Investigations: It is important to remember that unlike other

Railway structures, the ground surrounding a tunnel can act as a supporting
mechanism, or loading mechanism, or both, depending on the nature of the
ground, the tunnel size, and the method and sequence of constructing the
tunnel.

Thus, for tunnel designers and contractors, the rock or soil surrounding a
tunnel is a construction material, just as important as the concrete and steel
used on the job.

Subsurface investigation is the most important type of investigations to

obtain ground conditions, as it is the principal means for:

 Defining the subsurface profile (i.e. stratigraphy, structure, and principal

soil and rock types)
 Determining soil and rock material properties and mass characteristics
 Identify geological anomalies, fault zones and other hazards (squeezing
soils, methane gas, etc.)
 Defining hydro geological conditions (groundwater levels, aquifers,
hydrostatic pressures, etc.) and
 Identifying potential construction risks (boulders, etc.).

Subsurface investigations typically consist of:

 Borings,
 In situ testing,
 Geophysical investigations, and
 Laboratory material testing.

Each of these investigation techniques is briefly discussed below:

 Borings: to identify the subsurface stratigraphy, and to obtain

disturbed and undisturbed samples for visual classification and
laboratory testing.

Vertical and slightly inclined test borings and soil/rock sampling are key
elements of any subsurface investigations for tunneling projects. The
location, depth, sample types and sampling intervals for each test
boring must be selected to match specific project requirements,
topographic setting and anticipated geological conditions.

Table below presents general guidelines from AASHTO (1988) for

determining the spacing of boreholes for tunnel projects:

7
 Guidelines for Vertical/Inclined Borehole Spacing

Ground Conditions Typical Borehole Spacing

(feet)
Cut-Cover Tunnels 100 to 300
Rock Tunneling
Adverse Conditions 50 to 200
Favorable Conditions 500 to 1000
Soft Ground Tunneling
Adverse Conditions 50 to 100
Favorable Conditions 300 to 500
Mixed Face Tunneling
Adverse Conditions 25 to 50
Favorable Conditions 50 to 75

The above guideline can be used as a starting point for determining the
number and locations of borings. However, especially for a long tunnel
through a mountainous area, it may not be economically feasible or the time
sufficient to perform borings accordingly. Therefore, engineering judgment
will need to be applied by experienced geotechnical professionals to adapt
the investigation program.

In general, borings should be extended to at least 1.5 tunnel diameters

below the proposed tunnel invert. However, if there is uncertainty regarding
the final profile of the tunnel, the borings should extend at least two or three
times the tunnel diameter below the preliminary tunnel invert level.

Horizontal boreholes along tunnel alignments provide a continuous record of

ground conditions and information which is directly relevant to the tunnel
alignment. Although the horizontal drilling and coring cost per m may be
much higher than the conventional vertical/inclined borings, a horizontal
borings can be more economical, especially for investigating a deep
mountainous alignment, since one horizontal boring can replace many deep
vertical conventional boreholes.

A deep horizontal boring will need some distance of inclined drilling through
the overburden and upper materials to reach to the depth of the tunnel
alignment. Typically the inclined section is stabilized using drilling fluid and
casing and no samples are obtained. Once the bore hole reached a
horizontal alignment, coring can be obtained using HQ triple tube core
barrels.

All borings should be properly sealed at the completion of the field

exploration, if not intended to be used as monitoring wells.

 In situ tests: to obtain useful engineering and index properties by

testing the material in place to avoid the disturbance inevitably caused by
sampling, transportation and handling of samples retrieved from boreholes;
in situ tests can also aid in defining stratigraphy.

8
 In situ tests are used to directly obtain field measurements of useful soil and
rock engineering properties. In soil, in situ testing include both index type
tests, such as the Standard Penetration Test (SPT) and tests that determine
the physical properties of the ground, such as shear strength from cone
penetration Tests (CPT) or Vane Shear Tests (VST) and ground deformation
properties from pressure meter tests (PMT). The parameters to be tested
would depend on the nature of underground strata viz. Rock or Soil.

It is recommended that parameters to be tested should be finalized in

advance in consultation with design engineers. Appropriate test methods
should then be used to obtain those parameters with an acceptable degree of
validity & reliability.

 Geophysical tests: to quickly and economically obtain subsurface

information (stratigraphy and general engineering characteristics) over a
large area to help define stratigraphy and to identify appropriate locations for
performing borings.

Geophysical tests are indirect methods of exploration in which changes in

certain physical characteristics such as magnetism, density, electrical
resistivity, elasticity, or a combination of these are used as an aid in
developing subsurface information.

Geophysical methods provide an expeditious and economical means of

supplementing information obtained by direct exploratory methods, such as
borings, test pits and in situ testing; identifying local anomalies that might
not be identified by other methods of exploration; and defining strata
boundaries between widely spaced borings for more realistic prediction of
subsurface profiles.

Typical uses of geophysical tests include determination of the top of bedrock,

the depth to groundwater, the presence of voids, the location and depth of
utilities, the location and depth of existing foundations, and the location and
depth of other obstruction etc.

In addition, geophysical testing can also obtain stiffness and dynamic

properties which are required for numerical analysis. Geophysical testing can
be performed on the surface, in boreholes (down or cross hole), or in front of
the TBM during construction.

It is recommended that Geophysical method to be used should be finalized in

advance in consultation with design engineer.

Typical applications for geophysical tests are presented in Table below:

9
 Applications for Geophysical Testing Methods (after AASHTO, 1988)

Geological Conditions to Useful Geophysical Techniques

be Investigated SURFACE SUBSURFACE
Stratified rock and soil Seismic Refraction Seismic Wave
units (depth and thickness Propagation
of layers)
Depth to Bedrock Seismic Refraction Seismic Wave
Electrical Resistivity Propagation
Ground Penetrating
Radar
Depth to Groundwater Seismic Refraction
Table Electrical Resistivity
Ground Penetrating
Radar
Location of Highly Electrical Resistivity Borehole TV Camera
Fractured Rock and/or
Fault Zone
Solution Cavities Electrical Resistivity Borehole TV Camera
Ground Penetrating
Radar Gravity

It is important to note that the data from geophysical exploration must

always be correlated with information from direct methods of exploration that
allow visual examination of the subsurface materials, direct measurement of
groundwater levels, and testing of physical samples of soil and rock.

Direct methods of exploration provide valuable information that can assist

not only in the interpretation of the geophysical data, but also for
extrapolating the inferred ground conditions to areas not investigated by
borings. Conversely, the geophysical data can help determine appropriate
locations for borings and test pits to further investigate any anomalies that
are found.

 Laboratory testing: provides a wide variety of engineering

properties and index properties from representative soil samples and rock
core retrieved from the borings.

Detailed laboratory testing is required to obtain accurate information for

design and modeling purposes.

Soil Testing: Detailed soil laboratory testing is required to obtain accurate

information including classification, characteristics, stiffness, strength, etc.
for design and modeling purposes. Testings are performed on selected
representative samples (disturbed and undisturbed) in accordance with
relevant standards.

Table below shows common soil laboratory testing for tunnel design
purposes:

10
 Parameter Test Method
Soil identification  Particle size distribution
 Atterberg limits wl, wp
 Moisture Content
 Unit weights γ ,γd , γz
 Permeability k.
 Core recovery
Mechanical properties  Unconfined compressive
strength
 Triaxial compressive strength
for determination of Friction
angle Φu , Φ and Cohesion cu,
c.
 Consolidation Test for
determination of
Compressibility mv, cv
Mechanical properties determined by  Shear strength ζu (Vane-test).
field testing • Penetration N (Standard
Penetration Test).
 Deformability E (Plate bearing,
Dilatometer)

Rock Testing: Standard rock testing evaluates physical properties of the

rock including density and mineralogy. The mechanical properties of the
intact rock core include uniaxial compressive strength, tensile strength, static
and dynamic elastic constants, hardness, and abrasive indices.

Table below summarizes common rock laboratory testing for tunnel design
purposes:

Common Laboratory Tests for Rock (after USACE 1997)

Parameter Test Method

Index Properties  Density
 Porosity
 Moisture Content
 Slake Durability
 Swelling Index
 Point Load Index
 Hardness
 Abrasivity
Strength  Uni-axial compressive
strength
 Tri-axial compressive
strength
 Tensile strength (Brazilian)
 Shear strength of joints
Deformability  Young’s modulus
 Poisson’s ratio

11
 Time dependence  Creep characteristics
Permeability  Coefficient of permeability
Mineralogy and grain sizes  Thin-sections analysis
 Differential thermal analysis
 X-ray diffraction

It is desirable to preserve the rock cores retrieved from the field properly for
years until the construction is completed and disputes/claims are settled.
Common practice is to photograph the rock cores in core boxes and possibly
scan the core samples for review by designers and contractors.

In addition to typical geotechnical, geological, and geo-hydrological data,

subsurface investigation for a tunnel project must consider the unique needs
for different tunneling methods, i.e. cut-and-cover, drill and-blast, NATM.

Table below shows special considerations for various tunneling methods.

Special investigation needs related to construction methods

Construction Method Special Requirements

Drill and blast Data needed to predict stand–up time for the size
and orientation of tunnel
Road header Need data on jointing & hardness of rock
Tunnel Boring Machine While data required would depend on kind of
machine being deployed, the following information
is useful:
 Data required to determine cutter costs and
penetration rate
 Data to predict stand-up time to determine
if open-type machine will be ok or if full
shield is necessary.
 Data for assessing face stability
 Data for full characterization of all potential
mixed-face conditions.
 Reliable estimate of groundwater pressures
and of strength and permeability of soil to
be tunneled.

NATM Generally requires more comprehensive

geotechnical data and analysis to predict behavior
and to classify the ground conditions and ground
support systems into four or five categories based
on the behavior.
Portal Construction Need reliable data to determine most cost-
effective location of portal and to design
temporary and final portal structure.
Construction Shafts Should be at least one boring at every proposed
shaft location.

12
 Various geological conditions demand special considerations for subsurface
investigations as summarized in the table below

Construction Method Special Requirements

Hard or Abrasive Rock Difficult and expensive for TBM or road header.
Investigate, obtain samples and conduct lab
tests to provide parameters needed to predict
rate of advance and cutter costs.

Mixed Face Should be characterized carefully to determine

nature and behavior of mixed-face and
approximately length of tunnel likely to be
affected for each mixed-face condition.

Karst Potentially large cavities along joints.

High stress Could strongly affect standup time and

deformation patterns both in soil and rock
tunnels. Should evaluate for rock burst for
popping rock in particularly in deep tunnels.
Adverse Geological 1. Faults
Features  Known or suspected active faults.
Investigate to determine location and
estimate likely ground motion.
 Inactive faults but still sources of difficult
tunneling conditions.
 Fault gouge sometimes a problem for
strength and modulus.
2. Groundwater: Groundwater is one of most
difficult and costly problems to control. Must
investigate to predict groundwater as reliably
as possible.
3. Thrust Zones & Shear Zones.
4. Adverse Bedding & jointing.

These Geo-technical investigations provide factual information about the

distribution and engineering characteristics of soil, rock and groundwater at
a site, allowing an understanding of the existing conditions sufficient for
developing an economical design, determining a reliable construction cost
estimate, and reducing the risks of construction.

iii) Detailed Geological Mapping

A detailed geologic mapping effort should be carried out which includes

mapping & plotting of Joints, faults, and bedding planes. The geologist must
then project the geologic conditions to the elevation of the proposed tunnel
so that tunneling conditions can be assessed.

13
 Geologic mapping collects detailed geologic data systematically, and is used
to characterize and document the condition of rock mass such as:

 Discontinuity type
 Discontinuity orientation
 Discontinuity infilling
 Discontinuity spacing
 Discontinuity persistence
 Weathering

By interpreting and extrapolating all these data, the geologist should have a
better understanding of the rock conditions likely to be present along the
proposed tunnel and at the proposed portal and shaft excavations. In
addition, the following surface features should also be observed and
documented during the geologic mapping program:

 Slides, new or old, particularly in proposed portal and shaft areas

 Faults
 Rock weathering
 Sinkholes and karstic terrain
 Groundwater springs

Based on detailed geological mapping, it should be possible to divide the

tunnel alignment into zones of consistent rock mass condition. Criteria for
zonation would be site specific, but factors involving intact rock, rock mass,
and excavation system characteristics should be considered. Each zone
should be characterized in terms of average expected condition as well as
extreme conditions likely to be encountered.

Assumed Geology and ground classes along a tunnel

The mapping data will also help in targeting subsurface investigation borings
and in situ testing in areas of observed variability and anomalies.

14
iv) Detailed Hydrological survey & Groundwater investigation

Hydrogeological work to be carried out at this stage includes measurement of

groundwater levels or pressures in boreholes, permeability tests using
packers in boreholes, and sometimes pumping tests.

Groundwater is a critical factor for tunnels since it may not only represent a
large percentage of the loading on the final tunnel lining, but also it largely
determines ground behavior and stability for soft ground tunnels; the inflow
into rock tunnels; the method and equipment selected for tunnel
construction; and the long-term performance of the completed structure.

Accordingly, for tunnel projects, special attention must be given to defining

the groundwater regime, aquifers, and sources of water, any perched or
artesian conditions, depth to groundwater, and the permeability of the
various materials that may be encountered during tunneling.

Related considerations include the potential impact of groundwater lowering

on settlement of overlying and nearby structures, utilities and other facilities;
other influences of dewatering on existing structures; pumping volumes
during construction; the potential impact on water supply aquifers; and
seepage into the completed tunnel etc.

Groundwater investigations typically include most or all of the following

elements:

 Observation of groundwater levels in boreholes

 Assessment of soil moisture changes in the boreholes
 Installation of groundwater observation wells and piezometers
 Borehole permeability tests (rising, falling and constant head tests;
packer tests, etc.)
 Geophysical testing
 Pumping tests

During subsurface investigation drilling and coring, it is particularly important

for the inspector to note and document any groundwater related
observations made during drilling or during interruptions to the work when
the borehole has been left undisturbed. Even seemingly minor observations
may have an important influence on tunnel design and ground behavior
during construction.

Observation wells and piezometers should be monitored periodically over a

prolonged period of time to provide information on seasonal variations in
groundwater levels. Monitoring during construction provides important
information on the influence of tunneling on groundwater levels, forming an
essential component of construction control and any protection program for
existing structures and facilities.

15
 v) Structure & utility preconstruction survey

Structures located within the zone of potential influence may experience a

certain amount of vertical and lateral movement as a result of soil movement
caused by tunnel excavation and construction in close proximity (e.g. cut-
and-cover excavation, shallow soft ground tunneling, etc.). If the
anticipated movement may induce potential damage to a structure, some
protection measures will be required, and a detailed preconstruction survey
of the structure should be performed. Preconstruction survey should
ascertain all pertinent facts of pre-existing conditions, and identify features
and locations for further monitoring.

The requirement for utility survey varies with tunneling methods and site
conditions. Cut and-cover tunnel and shallow soft ground tunnel
constructions, particularly in urban areas, extensively impacts overlying and
adjacent utilities. Water, sewerage, storm water, electrical, telephone, fiber
optic and other utility mains and distribution systems may require
excavation, rerouting, strengthening, reconstruction and/or temporary
support, and may also require monitoring during construction.

2.3 Geo-technical Investigations During Construction phase

For tunneling projects it is generally essential to perform additional

subsurface investigations and ground characterization during construction.
Such construction phase investigations serve a number of important
functions like:

 To verify initial ground support selection & for design/redesign.

 Documenting existing ground conditions for reference in case of
contractual claims.
 Assessing ground and groundwater conditions ahead of the advancing
face to reduce risks and improve the efficiency of tunneling operations.
This enables forewarning of adverse tunneling conditions like potential
high water inflow, very poor ground etc.
 Verification of conditions assumed for final tunnel lining design,
including choice of unlined tunnel.
 Mapping for the record, to aid in future operations, inspections, and
maintenance work.

A typical construction phase investigation program would likely include

some or all of the following elements:

 Subsurface investigation (borings and geophysical) from the ground

surface.
 Additional groundwater observation wells and/or piezometers.
 Additional laboratory testing of soil and rock samples.
 Geologic mapping of the exposed tunnel face: with due safety
precautions.
 Geotechnical instrumentation

16
  Probing in advance of the tunnel heading from the face of the tunnel:
typically consists of drilling horizontally from the tunnel heading by
percussion drilling or rotary drilling methods.
 Pilot Tunnels (and shorter exploratory adits): are small size tunnels
(typically at least 2m by 2 m in size) that are occasionally used for
large size tunnels in complex geological conditions.

Pilot tunnels, when used, are typically performed in a separate contract

in advance of the main tunnel contract to provide prospective bidders a
clearer understanding of the ground conditions that will be
encountered. Consideration can also be given to locating the pilot
tunnel adjacent to the proposed tunnel, using the pilot tunnel for
emergency exit, tunnel drainage, tunnel ventilation, or other purposes
for the completed project.

3.0 Assessing Exploration requirements of a Tunneling Project:

3.1 Because of the complexities of geology and the variety of functional

demands, no two tunnels are alike. It is therefore difficult to give hard and
fast rules about the required intensity of explorations or the most appropriate
types of exploration. None the less, following can help in the planning of
explorations:

(a) Plan explorations to define the best, worst, and average conditions for
the construction of the underground works; locate and define conditions
that can pose hazards or great difficulty during construction.
(b) Use qualified geologists to produce the most accurate geologic
interpretation so as to form a geological model that can be used as a
framework to organize data and to extrapolate conditions to the
locations of the underground structures.
(c) Determine and use the most cost-effective methods to discover the
information sought.
(d) Anticipate methods of construction and obtaining data required to select
construction methods and estimate costs.
e) Anticipate potential failure modes for the completed structures and
required types of analysis, and obtain the necessary data to analyze
them (e.g., in situ stress, strength, and modulus data for numerical
modeling).
f) Drill at least one boring at each shaft location and at each portal.
g) Special problems may require additional explorations.

3.2 The complexity and size of an underground structure has a bearing on the
required intensity of explorations. A long tunnel of small diameter does not
warrant the expense of detailed explorations, and a tunneling method able to
cope with a variety of conditions is required. On the other hand, a large
underground structure such as an underground railway station is more
difficult to construct and warrants detailed analyses that include closely
spaced borings, reliable design data, and occasionally a pilot tunnel.

3.3 Frequently, even the most thorough explorations will not provide sufficient

17
 information to anticipate all relevant design and construction conditions.
Here, the variation from point to point may be impossible to discover with
any reasonable exploration efforts. In such instances, the design strategy
should deal with the average or most commonly occurring condition in a
cost-effective manner and provide means and methods to overcome the
worst anticipated condition, regardless of where it is encountered.

3.4 In mountainous terrain, it is often difficult or very expensive to gain access

to the ground surface above the tunnel alignment for exploratory drilling.
Many tunnels have been driven with borehole data available only at the
portals. In such instances, maximum use must be made of remote sensing
and surface geologic mapping, with geologic extrapolations to tunnel depth.
The strategy may also include long horizontal borings drilled from the portals
or probe holes drilled from the face of the advancing tunnel.

3.5 The intensity of explorations can be measured in several meaningful ways:

 Cost of full geotechnical exploration program (borings, testing,

geophysics) as percentage of construction cost.
 Typical spacing of boreholes.
 Number of meters of borehole drilled for each 100 m of tunnel.

3.6 The required intensity of explorations will vary with factors like complexity of
geology, project environment, depth of tunnel, accessibility for explorations,
and cost of individual borings etc.

3.7 A practical guide for assessing the suitability of an exploration program is

shown in Table below. The guide starts with a relatively simple base case and
employs factors up or down from there. The base case considered is a 6 m
drainage tunnel through moderately complex geology in a suburban area at a
moderate depth of about 30 m.

Table: Guidelines for Assessing Exploration Needs for Tunnels and in

Rock (US Army Manual EM-1110-2-2901)
Cost of Boring and Borehole Borehole
Testing as % of Spacing Length per
Construction cost 100 m of
Tunnel
Base case 0.4-0.8 150-300 m 15-25 m
Extreme range 0.3-10 15-1,000 m 5-1,000 m
For conditions noted, multiply base case by the following factors:
Simple geology 0.5 2-2.5 0.5
Complex 2-3 0.3-0.5 2-3
geology
Rural 0.5 2-2.5 0.5
Dense urban 2-4 0.3-0.4 2-5
Deep tunnel 0.8-1 Increase borehole spacing in proportion to depth of
tunnel

18
 Poor surface 0.5-1.5 5-10+ Variable
access
Shafts and NA At least one each NA
portals
Special 1.5-2 0.2-0.5 locally
problems

The specific scope and extent of the investigation must be appropriate for
the size of the project and the complexity of the existing geologic conditions;
must consider budgetary constraints; and must be consistent with the level
of risk considered acceptable.

3.8 Since unanticipated ground conditions are most often the reason for costly
delays, claims and disputes during tunnel construction, a project with a more
thorough subsurface investigation program would likely have fewer problems
and lower final cost.

According to experience from USA (R.A.Robinson, M.A.Kucker, J.P.Gildner),

over 55% of claims relate to unforeseen ground conditions and they
decrease with increasing exploration, as shown in Table below:

Meter of exploration boring per Claims relative to bid price

meter of tunnel alignment
0.5 30-40%
1 <20%
1.5 <10%

3.9 U.S National committee on Tunneling Technology (USNC/TT) recommended

in year 1995 the following level of effort for geotechnical site exploration:

1. Site exploration budgets should average 3.0% of the estimated project

cost.
2. Boring footage should average 1.5 linear ft of borehole per route ft of
tunnel.

3.10 While above tables can be referred to for guidance purpose, the extent of an
exploration program should be based on specific project requirements and
complexity, rather than strict budget limits.

However, for most tunnels, especially tunnels in mountainous areas, the cost
for a comprehensive subsurface investigation may be prohibitive. The
challenge to geotechnical professionals is to develop an adequate and
diligent subsurface investigation program that can improve the predictability
of ground conditions within a reasonable budget and acceptable level of risk.

4.0 An effective & economical Geotechnical investigation Program

should include:

a) Planning of a comprehensive Geotechnical investigation Program in

19
 active consultation with experienced geotechnical engineers, geologists
& designers.

b) “What”, “Why”, “Where”, “How” & “How much” for each Geotechnical
parameter to be tested/investigated should be included in the
Geotechnical investigation Program.

c) Phasing the investigation, as discussed earlier to better match and limit

the scope of the investigation to the specific needs for each phase of the
project, and Utilizing existing information and the results of geologic
mapping and geophysical testing to more effectively select locations for
investigation. Emphasis can be placed first on defining the local
geology, and then on increasingly greater detailed characterization of
the subsurface conditions and predicted ground behavior.
d) Keeping the investigation program flexible enough so as to enable taking
up of additional investigations as per unexpected requirements that
emerge during course of work.

20
Chapter 2: Choice of Tunnel system, Alignment & Shape/Size of cross-section

1.0 An adequate geological-geotechnical exploration and a thorough description of

the ground in the early planning stages is important for deciding:-

a) Choice of tunnel system

b) Choice of the alignment
c) The shape of the cross-section

a) Choice of tunnel system

The tunnel system comprises all underground works that are necessary to
achieve the planned use and ensure the safety of persons and material assets.
Besides the main tunnel tube(s), the tunnel system may comprise, e.g. cross-
passages, adits and shafts as escape routes or other ancillary structures such
as ventilation shafts or caverns for technical equipment.

The choice of the tunnel system is based mainly on operational, organizational

and safety considerations. The ground conditions and the topography may also
have an influence on the selection of the tunnel system.

b) Choice of alignment

The vertical and horizontal alignment of the tube(s) also depends on several
factors such as:

 Maximum ruling gradient: Ruling grade permissible in tunnels should be

smaller than in the open air, owing to:-

 Reduced rail-wheel adhesion in tunnels mainly due to presence of

moisture in tunnels: This causes decrease in the traction force in tunnels.
 Increased air resistance in tunnels: The magnitude of air resistance is
known to depend on the relative velocities of wind and train, greater
resistance upwind than downwind, as wells as on the relative cross-
section areas of tunnel and train. Resistance is especially large in single
track tunnels which are comparatively narrow.

If possible, maximum grades in straight tunnel should not exceed 75% of the
ruling gradient of the line. Grades in curved tunnels should be compensated for
curvature in the same manner as for open sections (i.e. outside the tunnel).

 Permitted maximum degree of curve

 The drainage considerations during construction and operation
 The accessibility and natural hazards in the portal areas
 The ground conditions

21
 If possible, the alignment should be adapted to the ground conditions in an
early phase of the project, as hazards and the respective construction time and
cost risks can be avoided or reduced by the choice of a different alignment.

Aspects of execution or operation and safety (such as the necessity of

intermediate adits, ventilation shafts or escape adits) may also influence the
choice of the alignment. This is particularly true for long tunnels.

c) Shape & dimensions of the cross section

The shape and the dimensions of the cross section of tunnel are determined
essentially by

i. The serviceability requirements associated with the use of the tunnel

ii. The geological-geotechnical conditions and
iii. Construction aspects

i. The serviceability requirements associated with the use of the

tunnel

The required dimensional/clearance profile is a key factor in the

determination of the cross section of the tunnel. Railway Schedule of
Dimensions is to be followed to ensure required clearances.

Other serviceability criterions relevant for making choice of cross section are:

 Additional space requirements for operating and safety equipment (cable

installations, signaling systems, signage, lighting, ventilation, etc.)
 Aerodynamic requirements
 Drainage requirements
 Maintenance requirements
 Requirements arising from the safety and rescue concept (escape routes
within the tunnel, availability of the facilities in emergencies)

ii. The geological-geotechnical conditions

The shape and the size of the cross section depend also on the ground
conditions, as the latter determine the extent of the required support
measures in the construction stage (tunnel support) and in the service
stage (permanent lining).

Unacceptable reduction in size of the opening due to ground convergence

must be avoided by means of additional excavation to account for ground
deformations and corresponding support measures.

22
 iii. Construction aspects

 Economic considerations and the availability of the necessary equipment

may be decisive for the construction method and have, therefore, a
considerable influence on the shape of the cross section.

 In the determination of the shape and dimensions of the cross section

attention must be given to tolerances with respect to driving accuracy,
construction tolerances and surveying tolerances.

In contrast to TBM or shield tunneling, the cross section of tunnels excavated

by conventional methods can be freely chosen within the constraints of the
geological conditions.

2.0 The main shapes used for railway tunnels are:

 D Shape: Economical (as its profile suits the requirements of SOD), Used
for hard rocks.

 Horseshoe cross section: The horse-shoe shape has a semi-circular

roof together with arched sides and curved invert. This cross-section
offers a good resistance to external ground pressure and is suitable for
soft rocks.

 Elliptical Shape: Suited for water bearing soils or soft grounds, economical
choice (due to its profile) compared to Circular cross section.

23
  Circular cross section: This shape is strong in offering resistance to
external pressure caused by water, water bearing soils or soft grounds. This
is the best theoretical section for resisting internal or external forces and it
provides the greatest cross sectional area for the least perimeter. The
circular section is often uneconomical for railways as more filling will be
required for obtaining flat base. It is best suited for tunnels driven by the
TBM/shield method.

Weak rock zones, squeezing or swelling rock and soft ground (soils) require a
circular cross section or at least a horseshoe-shaped cross section including an
invert arch.

24
 CHAPTER 3: Tunnel excavation methods

1.0 Selection of a particular tunnel excavation depends largely on:-

 Type of ground
 Size of tunnel
 Availability of resources (machinery/equipment, funds & time)

Commonly used Tunnel excavation methods can be grouped under the

following categories:

A. Excavation Methods for Rock Tunnels

B. Excavation Methods for Soft Ground Tunnels

These are discussed below:-

A. Excavation Methods for Rock Tunnels:

The three commonly used excavation methods for rock tunnels are:-

i) Drill and Blast (Full Face or Partial Face Excavation)

ii) Road Header (Full Face or Partial Face Excavation)
iii) TBM (Full Face)

These methods are generally used separately but may also be used in
combination.

i) Drill and Blast (Full Face or Partial Face Excavation):

This excavation method has been used since a long time & still remains
the conventional method for noncircular cross sections and also for
short length circular tunnels. This excavation method involves the cycle
of drilling, loading, blasting, scaling & mucking).

A key decision to be taken by engineers is whether to go for “Full Face

Excavation” or “Partial Face Excavation”.

Full Face Excavation & Partial Face Excavation:

Full-Face Excavation: Excavating the complete tunnel section in one

operation is termed as Full Face Excavation. Wherever practical Full
Face Excavation is preferred mainly for its superior rate of progress &
ease in construction. The decision for excavating full-face has to be
taken after careful consideration of the geology, the size (or span) of
the opening, and the stand-up time.

Partial Face Excavation: Large openings or openings in weak rocks

are less stable than small ones. Therefore, in many cases the tunnel
cross section is not excavated at once, but in parts. This type of

25
 excavation is called Partial Face Excavation.

The various types of partial face excavations are:

a) Heading and Benching. This method involves excavation of top heading

first. Excavation of the bench is done only after securing the top heading.
With the stand-up time problem eliminated (unless there will be a problem
with wall stability), longer increments of bench can be excavated.

1. Top Heading (also called calotte) 2. Benching

A ramp needs to be constructed for accessing the heading face if the

gap between faces of top heading & bench warrants so. If the
heading and the bench are excavated simultaneously, then the ramp
must be every now & then moved forward.

Installation of rock reinforcement in a top heading presents no special

problems. However, when steel ribs are used, the necessity for a full-
strength steel rib arch creates a problem at the abutments. The arch must
have a temporary foundation while the bench beneath it is excavated. Wall
plates are installed longitudinally beneath the ribs at the top heading invert.
A wall plate is a horizontal structural steel member placed under the arch to
act as an abutment and spread the reaction while the bench is being taken.
For smaller or lightly loaded ribs, the wall plate is a single wide flange beam

26
 with its web horizontal; arch and post segments fit inside its flanges. For
heavier loads or larger spans, a pair of beams joined together, with webs
vertical, is located directly beneath or over the arch/post flanges.

b) Multiple drift Advance: If the stand-up time is insufficient for advance by

heading and bench method, because of either the geology or large spans, the
top heading and/or benches must be divided into two or more drifts.

This is advantageous because the reduced span increases stand-up time, the
reduced volume decreases mucking time, and time required to install
support or reinforcement is also reduced. When using steel sets, the
appropriate final arch segment is used and supported temporarily on one or
more steel posts. When the adjacent drift is excavated, the next arch
segment is erected, connected, posted, and so on. Once the wall plates are
in place and the full arch erected, the temporary posts are removed.

While tunnel excavation from top down is preferred, in exceptionally poor

ground it may be necessary to work from the bottom up. Driving bottom
sidewall drifts first permits concreting abutments and eliminates having to
establish, undercut, and reestablish support.

Some well-established schemes of multiple drift excavation are:-

a)Core heading: This is also known as the German heading method. It

consists of excavating and supporting first the side and top parts of the cross
section and subsequently the central part (core). The ring closure at the
invert comes at the end. The first gallery also serves for exploration. The
crown arch is founded on the side galleries thereby keeping the related
settlements small.

b) Old Austrian Tunneling Method: This method is schematically represented

in Figure below:-

27
 The characteristic feature of this method is the crown slot. The simultaneous
work in several excavation faces allows a fast advance.

c) Sidewall drift: The side galleries are excavated and supported first. They
serve as abutment for the support of the crown, which is subsequently
excavated. This method is preferred in soils/rocks of low strength. Note that
a change from top heading to sidewall drift is difficult to accomplish.

In addition to above three, many other variations of multiple drift sequence

are also in practice.

Drill-and-blast are best suited for hard rocks, non-circular cross sections &
relatively short tunnels (where use of TBM/Road header is uneconomical) &
can also be used when encountering too great a variety of geologies or other
specific conditions such as mixed face, squeezing ground, etc. It is suited to
any type of tunnel cross section. Appropriate controlled blasting technique
needs to be implemented at site to reduce over breaks & minimize damage
outside the minimum excavation line.

28
ii) Excavation by Road header:

A road header, is a piece of excavating equipment consisting of a boom-

mounted cutting head, a loading device usually involving a conveyor, and a
crawler travelling track to move the entire machine forward into the rock
face.

The cutting head can be a general purpose rotating drum mounted in line or
perpendicular to the boom, or can be special function heads such as jack-
hammer like spikes, compression fracture micro-wheel heads like those on
larger tunnel boring machines, a slicer head like a gigantic chain saw for
dicing up rock, or simple jaw-like buckets of traditional excavators.
Road headers are used for moderate rock strengths and for laminated or
joined rock. The cutter is mounted on an extension arm (boom) of the
excavator and cuts the rock into small pieces. Thus, over profiling can be
limited and also the loosening of the surrounding rock is widely avoided.
One has to provide for measures against dust (suction or water spraying).
The required power of the motors increases with rock strength.

The width of tunnel excavated varies from slightly more than the width of
the machine body plus treads to twice that width. Much less heading
equipment is required and start-up costs are only a fraction of that for TBM
excavation. The compactness, mobility, and relatively small size of the road
header combined with simultaneous mucking makes it practical to install
rock bolts and/or shotcrete quickly and easily.

The principal constraint on road headers is that they currently are usable
only in rock of less than about 12,000 psi compressive strength. Somewhat
stronger rock can be cut, or chipped away, if it is sufficiently fractured.

This method could also be called partial face mechanization. Whereas TBMs
are generally purpose-built, road headers are nearly "off-the-shelf’
equipment requiring relatively little lead time.

Excavation by road header is suited for any type of tunnel cross sections &
may be done either partial-face or full face.

29
iii) Excavation by Tunnel Boring Machine:

Tunnel boring machines are used as an alternative to drilling and

blasting (D&B) methods in rock. TBMs excavate circular cross sections with a
rotating cutter head equipped with disc cutters.

TBMs have the advantages of limiting the disturbance to the surrounding

ground and producing a smooth tunnel wall. This significantly reduces the
cost of lining the tunnel, and makes them suitable to use in heavily urbanized
areas.

TBM tunnels have very high start-up (pre-excavation) costs and

accompanying long lead time; the high rate of advance reduces the per-m
excavation cost. The decision on undertaking excavation by TBM requires
careful consideration of techno-economic factors.

B. Excavation Methods for Soft Ground Tunnels

Two principal Methods for tunneling in soft ground are:-

1. Multiple Drift Method:- This method has already been under “Excavation
methods for rock tunnels”. Fore poling is normally done before doing
excavation particularly in heading portion.
2. Excavation by Tunnel Shields:- The shield is a steel tube with a (usually)
circular cross section. Its front is equipped with cutters. The shield is pushed
forward into the ground by means of jacks.

The control of ground water is of utmost importance in soft ground tunneling.

To control groundwater dewatering & grouting are the most common
methods. Methods using “compressed air” & “freezing” are also sometimes
used.

30
 Chapter 4: Tunneling Methods

Tunneling methods are normally classified on the basis of excavation method

under the following categories:-

A) Conventional Tunneling
B) Mechanized Tunneling

The definition of what is “Conventional Tunneling” is rather arbitrary, and

subject to variations, depending also on the context. For the present
guidelines, the term conventional tunnel applies to any tunnel that is not
excavated by a Tunnel Boring Machine (TBM)/Shield. It may however be
noted that in tunneling the TBM method has these days become very
common and thus could also be regarded as “conventional” in many
countries.

Another popular classification is “Rock Tunneling Methods” & “Soft Ground

Tunneling” Methods.

Yet another classification is sometimes made into “NATM” & “Non NATM”
Tunnels; the former following NATM philosophy.

For these guidelines, we will be discussing tunneling methods under

categories of Conventional Tunneling & Mechanized Tunneling.
Features/principles of NATM (& NTM) Tunneling are being discussed under
separate section.

A) Conventional Tunneling:

Conventional Tunneling in the context of this report means the construction

of underground openings of any shape with a cyclic construction process
of:

• Excavation, by using the drill and blast methods or mechanical

excavators except any full face TBM
• mucking
• Placement of the primary (initial) support elements such as

 Steel ribs or lattice girders

 Soil or rock bolts
 sprayed concrete (shotcrete) or cast in situ concrete, not
reinforced or reinforced with wire mesh or fibres

 final or secondary lining (if required)

31
1.0 Principles of Conventional Tunneling

Conventional Tunneling is carried out in a cyclic execution process of

repeated steps of excavation followed by the application of relevant
primary support, both of which depend on existing ground conditions and
ground behaviour.

The Conventional Tunneling Method mainly using standard equipment and

allowing access to the tunnel excavation face at almost any time is very
flexible in situations or areas that require a change in the structural analysis
or in the design and as a result of this also require changes in the support
measures.
A standard set of equipment for execution of Conventional Tunneling may
consist of the following items:

 Jack Hammers/Drilling jumbo to drill holes for blasting, rock bolting,

water and pressure release, grouting etc.
 Road header or excavator in cases where blasting is not possible or not
economic.
 Lifting platform allowing the workers to reach each part of the tunnel
crown and of the tunnel face.
 Lifting equipment for handling/erection of steel sets.
 Loader or excavator for loading excavated material onto dump trucks.
 Dump trucks for hauling excavated ground.
 Shotcrete machines (robotic/non-robotic).

Using this standard set of equipment the following changes can easily be
applied during construction if ground conditions change or if monitoring
results require action:

 Increase or decrease of support, e.g. the thickness of shotcrete, number

and/or lengths of rock bolts per linear meter of tunnel, spacing and
dimensions of steel arches, number and lengths of forepoles, application
of shotcrete at the tunnel face, bolting the face etc.
 Variation of ring closure time.
 Variation of explosives charge per blasting round and variation of
detonator sequences.

Other variations in the design enable one to react to changes in the

stand-up time of the ground encountered:

 Increased or decreased length of excavation round (common round

lengths vary from 0.5 m to 4.0 m).
 Partial excavation by splitting the excavation face into the crown, bench,
and invert excavation steps or even further in pilot and sidewall galleries.

32
 In case exceptional ground conditions are encountered - regardless of
whether predicted or not - the Conventional tunneling Method can react with
a variety of auxiliary construction technologies like
• Grouting: consolidation grouting, fissure grouting, pressure grouting,
compensation grouting.

• Technologies to stabilize and improve the ground ahead of the

actual tunnel face like forepoling, pipe umbrella, horizontal jet grouting,
ground freezing etc.

Conventional Tunneling in connection with the wide variety of auxiliary

construction methods enables making the most appropriate choice to achieve
safe and economic tunnel construction even in situations with changing or
unforeseen ground conditions. It allows reacting in both directions -
depending on the ground - either changing to the less favourable or towards
the more favourable side. This flexibility makes Conventional tunneling the
most advantageous tunneling method in many projects.

The Conventional tunneling Method is preferred choice for tunneling under

highly variable ground conditions or for projects with variable shapes.

1.1 Conventional tunneling enables:

o A greater variability of the shapes.

o Better knowledge of the ground by using systematic exploratory

drillings at tunnel level ahead of the face.

o Greater variability in the choice of excavation methods according to

the ground conditions.

o Greater variability in the choice of excavation sequences according to

the ground conditions.

o Easier optimization of the primary support using the observational

method in special cases.

o A greater variability in the choice of auxiliary construction methods

according to the ground conditions.

1.2 Conventional tunneling is especially convenient for:

o Difficult ground with highly variable ground conditions

o Projects with highly variable shapes of cross section

o Projects with a higher risk of water inflow under high pressure

o Projects with difficult access

33
 o Short tunnels

2.0 Construction Methods for Conventional Tunneling:

2.1 Excavation Methods

The excavation methods for Conventional tunneling are:

o Drilling and blasting mainly applied in hard rock ground conditions

o Mechanically supported excavation mainly used in soft ground and in
weak rock conditions (using road headers, excavators with shovels,
hydraulic breakers etc.)

Both excavation methods can be used in the same project in cases with a
broad variation of ground conditions. In both excavation methods the
excavation is carried out step by step in rounds. The round length generally
varies from 4 m in good conditions to 1 m or less in soil and poor ground
conditions. The round length is the most important factor for the
determination of the advance speed.

The engineer shall prescribe or limit the choice of the method of excavation
only if there are compelling reasons based on project restrictions. The
responsibility of the selection of the excavation method should best be left
to the contractor, based on the engineer’s description of the ground
conditions and the design limits.

2.1.1 Excavation Sequence

Conventional tunneling allows full-face and the partial excavation of the

tunnel cross section. Besides the structural analysis an important criterion
for selecting the adequate excavation sequence is the length of the
individual excavation-steps/rounds, which depends on the stand-up time of
the ground without support. In good ground conditions the maximum round
length is limited by the acceptable tolerance for over break, which is mainly
an economic criterion when over break has to be filled up to the design line
of the tunnel circumference.

Both excavation types (full-face and the partial excavation) allow exploratory
drillings from the face at any time.

Full-face excavation is used for smaller cross sections and in good ground
conditions with long stand-up times. Since a high degree of mechanization of
the work and the use of large, high performance equipment has become
common, also bigger cross sections (70 to 100 m2 and more), even in difficult
rock conditions are sometimes excavated with the full-face method. In any
case, face stability shall be given serious consideration and often face support
- bolting, shotcrete etc. - becomes necessary.

34
 Full-face excavation allows the immediate closure of the primary support
ring, close to the excavation face.

Partial excavation is mainly used for big cross sections in soils and un-
favorable ground conditions. There are several types of partial excavation as
discussed earlier.

Partial excavation, allows the combination of the different excavation

methods in the same cross section, e.g. blasting in the top heading and
excavating the bench by using a mechanical excavator e.g. a road header.

The choice whether full-face or partial excavation is preferable depends on

ground properties but also sometimes on environmental aspects, on the
magnitude of settlements at the surface and economic considerations. In
special cases both excavation sequences can be used. However, frequent
changes in the type of excavation are uneconomical.

2.1.2 Primary Support

The purpose of the primary support is to stabilize the underground opening

until the final lining is installed.
In many cases it may become necessary to apply the support system in
combination with auxiliary constructional measures.

The most common elements for the primary support are

 Rock bolts

Local Rockbolting Systematic Rockbolting

35
 Rockbolting

 Shotcrete (not reinforced and reinforced- with fibres or wire mesh)

Shotcrete/SFRS Shotcrete/SFRS + Rockbolt

Shotcrete-Manual Shotcrete-by robotic arm truck

 Steel ribs and lattice girders

Steel Ribs + Lagging Steel Ribs + Wooden block packing

36
 Lattie Girders Lattice Girder placed at site after assembly

 Lagging & back fill concrete

These elements are applied individually or in combination in different types of

support depending on the assessment of ground conditions by the
responsible site engineers and by taking into account the corresponding
design.

In each round, elements of the primary support have to be placed up to the

excavation face for reasons of safety and analysis/ assessment of the actual
ground conditions.

2.1.3 Auxiliary Construction Measures

In special cases, the excavation work can only be carried out by means of
additional auxiliary construction measures. The auxiliary construction
measures can be classified in the following categories:

a. Ground improvement
b. Ground reinforcement
c. Dewatering

a) Ground improvement

Ground improvement means the application of methods that improve the

mechanical or hydraulic properties of the ground.

The main methods are:

i. Grouting
ii. Jet grouting
iii. Ground freezing

Ground improvement has normally to be carried out alternately to the

excavation and leads to interruptions of the excavation work. In special
cases ground improvement can be carried out from the surface or pilot
tunnels outside the future tunnel cross section.

37
 i) Grouting:

The different techniques for grouting are consolidation grouting, fissure

grouting, pressure grouting and compensation grouting.

Grouting can be carried out in the tunnel excavation as face grouting or as

radial grouting from the excavated tunnel or from a pilot tunnel. The most
commonly used grout material is cement. In special cases chemical products
such as resins or foams are also applied. In these cases the environmental
and safety restrictions have to be considered specially.

ii) Jet Grouting

Jet grouting is applied mainly horizontally or at a slightly upward or

downward angle from within the face of the tunnel. An improvement of the
roof arching behaviour is achieved by applying one or more layers of jet
grouting columns in stages corresponding to the excavation operations.

An improvement of the stability of the face is achieved by placing individual

jet columns parallel to the direction of advance in the working face.

Less common in tunneling is vertical or steeply inclined jet grouting, except

38
 in shallow tunnels where it is applied from the surface. From within the
tunnel vertical or steeply inclined jet grouting is mainly applied to underpin
the bottom of the roof arch.

iii) Ground freezing

The following ground freezing techniques are known to waterproof or

stabilize temporarily the ground:

• Continuous frozen bodies which provide long-term load-bearing. The

freezing is achieved by a drilled tube system, through which coolant is
pumped.

• Short-term, immediately effective local freezing of damp zones close

to the face or in the immediate vicinity outside the excavated cross
section. This is achieved by means of injection lances with liquid nitrogen
cooling.

b) Ground Reinforcement:

Ground reinforcement involves the application of methods that use the

insertion of structural elements with one predominant dimension. Bolts,
anchors, micro piles and spiles are such elements. The main methods of
application are pipe umbrellas; face bolting or radial bolting from a pilot bore.

Pipe umbrella:

Pipe umbrellas are specified to supplement the arch structure in the roof and
spring line regions as well as stabilization of the face and in advance of the
face immediately after the excavation. The pipe umbrella should extend at
least 30% beyond the face of the next excavation.

39
 Pipe Umbrella

Pipe forepole umbrella

Spiles:

Spiles are steel rods left in the ground for the local short-term stabilization
of the roof section and at the working face on the boundary of the
excavation.

The spiles rest on the first steel arch in front and should be at least 1.5
times as long as the subsequent advance in the excavation. Depending on
the type of soil, the spiles can be jacked, rammed or inserted in drill holes.

Face bolts:

Face bolts are often necessary to stabilize or reinforce the face. Depending
on the anticipated ground condition/behaviour, the relevant bolt type and
length have to be determined in the design. Practically any bolt type or
length is possible. As a protection against rock fall, spot bolts may be
sufficient whereas in difficult ground conditions (e.g. squeezing rock and
soils) systematic anchoring with a high number of long, overlapping steel or

40
 fibre glass bolts may be necessary. Face bolts are placed during the
excavation sequence, if necessary in each round or in predefined steps.

c) Dewatering and drainage:

In some cases the tunnel construction is only possible with the application of
special dewatering measures. According to the ground conditions and other
boundary conditions conventional vertical or horizontal wells or vacuum
drains can be used.

In the design of the dewatering measures environmental aspects have to be

considered, such as limits on lowering the ground water table, settlements,
etc.

In the case of low overburden, dewatering measures can be carried out from
the ground surface. In the other cases, dewatering has to be done from the
tunnel cross section or from pilot tunnels.

2.1.4 Placement of final (secondary) lining: An underground space excavated

by the Conventional tunneling Method may need a final (secondary)
lining in addition to the primary lining according to the requirements of the
project to:-

 Cater for all the final load cases

 Fulfill the final safety margin
 Include the necessary protection measures (e.g. water tightness)
 Guarantee the required service life time

Generally two options exist to construct the final (secondary) lining:

 Installation of an independent secondary lining that is normally

dimensioned to withstand all the final load cases. The secondary lining
can consist of shotcrete or cast in situ concrete. According to the
requirements of the project the final lining consists of unreinforced
concrete or reinforced concrete.
 Installation of additional layers of shotcrete to strengthen the primary
lining for all the final load cases.

3.0 Instrumentation and Monitoring

Field monitoring is an indispensable element of modern tunneling. The

purpose of the instrumentation may be:

o Checking the structural behaviour with respect to safety and/or

serviceability criteria, mainly during construction and in some cases
during service life.
o The quantification of structural response to a specific method of
construction and checking the effectiveness of specific support

41
 measures.
o The comparison of theoretical predictions with the actual structural
behaviour and the assessment of the material parameters of the
ground.
o Checking adjacent structures and facilities for their safety and
serviceability as a result of the construction of the tunnel.

Due to its quality, monitoring data can also be used for clearing disputes
between contractual partners or between the client and third parties.
Therefore a further objective is:

o Documentation related to the tunnel construction

B) Mechanized tunneling:

1.0 Mechanized tunneling offers many advantages; some of these are:-

 industrialization of the tunneling process , with ensuing reductions in

costsand construction times
 the possibility some techniques provide of crossing complex geological
andhydrogeological conditions safely and economically,
 the good quality of the finished product
 enhanced health and safety conditions for the workforce

However, there are still risks associated with mechanized tunneling, for the
choice of technique is often irreversible and it is often impossible to change
from the technique first applied or only at the cost of immense upheaval to
the design and/or the economics of the project.

Detailed analysis of the conditions under which the project is to be carried

out should substantially reduce this risk. The experience and technical skills
of tunneling machine operators are also an important factor in the reduction
of risks.

There are many options available these days for the construction of tunnels.
The selection of which tunnelling technique to use must be made on the basis
of the known and suspected ground conditions, in combination with other
aspects such as access, experience and skill of the officials/workers, as well
as costs. Adaptability of the technique to variability of the ground could also
be an important factor.

“Tunneling Shields” & “Tunnel Boring Machines” are the two principal types of
machines employed for mechanized tunneling. Strictly speaking, TBMs are
“unshielded” (i.e. are of Open type) and are used in hard rock whereas
Shields have “shield/s” under the protection of which the ground is excavated
and the tunnel support is erected. Shields are used in soft ground.

But quite often these two terms are used interchangeably as distinction
between two is getting blurred.

42
1.1 Tunneling shields:

In its simplest form a tunneling shield is a steel frame with a cutting edge on
the forward face. For circular tunnels this is usually a circular steel shell
under the protection of which the ground is excavated and the tunnel support
is erected. A shield also includes back-up infrastructure to erect the tunnel
support (lining) and to remove the excavated spoil.

There are two main types of tunnelling shield, one with partial and one with
full face excavation.

In partially-mechanized shields, an excavator or a partial cutter head/road

header works on the face. Partially-mechanized shields (also called boom-in-
shield tunneling machines) are used where the cost of full face tunnel boring
machines cannot be justified.

Manual excavation, i.e. by ‘hand’, is only considered for very special

applications, e.g. very short advances, due to the low advance rate. This
type of tunneling is called the manual shield technique.

Full face Shield are discussed under Shielded TBMs & Soft Ground TBMs;
however basic working principle of the same is being briefly described
below:-

Tunneling shields do not have an ‘engine’ to propel themselves forwards, but

push themselves forward using hydraulic jacks. In order to create the
necessary force to push the tunnel shield forwards, jacks are placed around
the circumference of the shield. These jacks push against the last erected
tunnel segment ring and also push the shield against the tunnel face in the
direction of the tunnel construction. Of course this principle does not work at
the start of the tunnel construction and therefore in the starting shaft a
reaction frame is necessary to take the jacking forces. The jacks can be
operated individually or in groups, allowing the shield to be steered in order
to make adjustments in line and level and to be driven in a curve if required.

When the shield has advanced by the width of a tunnel segment ring, the
jacks are retracted leaving enough room in the tail of the shield to erect the
next tunnel segment ring.

The support usually adopted with shield tunnelling these days is circular
segments. These segments form, when connected together, a closed support
ring. As the tunnel segments are connected together inside the shield tail,
the diameter of the completed tunnel segment ring is smaller than that of the
shield. This creates a gap between the ground and the tunnel lining. When
the shield is jacked further into the ground the size of this gap is between
approximately 50 and 250 mm. In less supporting soft ground it has to be

43
 expected that the ground settles by this value. This can result in the
softening of the ground and, especially with shallow tunnels, in the
settlements reaching the ground surface and having undesirable
consequences on surface or near surface structures. In order to avoid these
settlements, the gap is generally injected with mortar.

1.2 Tunnel boring machines:

1.2.1 Introduction:

TBMs exist in many different diameters, ranging from micro tunnel boring
machines with diameters smaller than 1 m to machines for large tunnels,
whose diameters are greater than 15 m (the largest TBMs are now in excess
of 19 m).

TBMs are available for many different geological conditions. This means that,
for example, the type of tunnel face support required and the excavation
procedure as well as numerous other technical requirements can be solved in
many different ways. Every tunnel is different and hence there are often
frequent technical advancements in this field.

Although TBMs are often designed for specific projects, i.e. with a specific
diameter and in order to cope with certain ground conditions, these days
refurbished machines are becoming more common and projects are actually
designed around the machines available. An example of this is when the
diameter of the new project is chosen to suit the old machine, with just the
cutter head being redesigned for the specific ground conditions expected.

Tunnel boring machines (except ‘Gripper’ type TBM for hard rock), have a
‘shield’. Although it should be noted that even a Gripper TBM can have a
small shield around the cutter wheel to avoid it catching on any rock as the
ground deforms under high pressures.

One of the general requirements for the use of a TBM is a consistent geology
along the route of the tunnel as the different cutting tools are only suitable
for a small variation in material characteristics. A universal machine for all
types of ground and soil conditions does not exist (although TBMs with
multiple modes of operation such as Mix-shields are being developed). The
combination of different cutting tools on the cutter head can increase the
application of machines to a greater range of ground conditions.

Although TBMs can have different mechanisms for moving through the
ground, most have to start outside and hence need a reaction frame to start
the drive. As the tunnel segments are erected within the tunnel shield, there
is a gap between the segments and the excavated ground. In order to
achieve a rigid connection between the ground and the tunnel lining, thus
preventing the ground from moving, the gap is injected with cement slurry.

44
 TBMs are often grouped under categories of “Hard Rock TBMs” & “Soft
Ground TBMs”.

1.2.2 Hard Rock TBMs:

Hard rock TBMs comprise four key sections, which make up the complete
machine. These are the boring section, consisting of the cutter head, the
thrust and clamping section, which is responsible for advancing the machine,
the muck removal section, which takes care of collecting and removing the
excavated material, and the support section, where the tunnel support is
erected.

Hard rock TBMs comprise following four key sections:-

(i) Boring section, consisting of the cutter head,

(ii) Thrust and clamping section, which is responsible for advancing the
machine,
(iii) Muck removal section, which takes care of collecting and removing the
excavated material, and
(iv) Support section, where the tunnel support is erected.

Hard Rock TBMs primarily fall under following categories:-

i) Gripper TBM: Open hard rock TBM - suited for boring in stable rock.
ii) Shielded TBM - shielded hard rock TBM - suited for tunneling in
varying rock formations that alternate between stable and unstable
formations.

Working principles of these TBMs are briefly described below:-

i) Gripper TBM :

The Gripper TBM is braced radially with grippers against the tunnel wall, with
hydraulic cylinders pressing the cutter head against the tunnel face to enable
a further section of tunnel to be excavated. The maximum boring stroke is
governed by the length of the pistons in the thrust cylinder.

The drilling system, i.e. the cutter head, is fitted with cutter rings (disks).
The rotating cutter head forces the disks against the tunnel face under high
pressure. In this process the disks roll over the tunnel face, thereby
loosening the native rock.

The excavated rock, or "chips" as it is commonly known, is collected in muck

bucket lips (openings in the cutter head) and discharged via hoppers onto a
conveyor belt. The excavated material is brought outside the tunnel by
conveyers.

45
 Typical advance of cutter head is approximately 0.7 to 1.2 m. After
completion of a boring stroke, the drilling process is interrupted and the
machine moved forwards, with the Gripper TBM being stabilized by an
additional support system. A new working cycle can begin when the gripper
shoes of the machine are once more engaged.

Unlike shielded TBMs, where tunnel support, e.g. segmental lining, is fixed
and does not change during tunnel construction, the tunnel support system,
when using a Gripper TBM, can vary depending on the ground quality. The
appropriate rock support devices can be installed immediately behind the
cutter head. These devices can include anchors, steel arches, shotcrete, and
even segmental linings.

The tunneling performance of a Gripper TBM depends essentially on the time

required to install rock supporting devices.

The Gripper machine enables comprehensive rock support measures to be

taken even right behind the cutter head.

ii) Shielded TBM

In contrast to Gripper TBMs, the body of the shield TBM has an extended
shield over the front section of the machine. This shield has the function of
supporting the ground and protecting the personnel, thus allowing safe
erection of the tunnel lining.

There are two basic types of shield TBMs for hard rock available; the single-
shield and double-shield.

The single-shield TBM in hard rock is mainly used in unstable conditions

where there is a risk of ground collapse. With these machines, the pushing
forces are maintained axially against the installed lining segments.

The Single Shield TBM belongs to a category of machines which are fitted
with an open shield. Tunneling machines described as open shields are
machines without a closed system for pressure compensation at the tunnel
face.

Protected by the shield, the Single Shield machine extends and drives
forward the tunnel practically automatically. In order to drive the tunnel
forwards, the Single Shield TBM is supported by means of hydraulic thrust
cylinders on the last segment ring installed. The cutter head is fitted with
hard rock disks, which roll across the tunnel face, cutting notches in it. These
notches dislodge largish chips of rock. Muck bucket lips, which are positioned
at some distance behind the disks, carry the extracted rock behind
the cutting wheel. The excavated material is brought outside the tunnel by
conveyers.

46
 The double-shield machine (or telescopic shield) combines the ideas of the
gripper and single-shield techniques and can therefore be applied to a variety
of geological conditions. The double-shield machine consists of a front shield
with cutter head, as well as a gripper section with gripper shoes, a tail shield
and auxiliary thrust jacks. Both parts of the machine are connected by a
section called the telescopic shield. The operating principle is based on the
gripper shoes pressing against the tunnel wall while excavation and segment
installation are performed at the same time. The system adds some flexibility
to allow the machine to work either in gripper mode or as a shield TBM.

1.2.3 Soft ground TBMs/Shields

The application of a TBM technique in less stable soft ground commonly

requires the face to be supported. This is in contrast to the open face TBMs
(often used in hard rocks) where the ground is able to support itself during
excavation by virtue of its significant strength and stand-up time.

In soft ground, with little or no standup time, the ground would simply
collapse into the machine and attempts to control the excavation of this
material and to prevent large displacements occurring within extensive
amounts of the ground around the tunnel heading would be very difficult. In
addition, for tunnels constructed below the groundwater table in permeable
materials, water flow into the tunnel must be controlled in order to prevent
the machine and tunnel from flooding.

Soft ground TBMs are designed to simultaneously provide immediate

peripheral and frontal support and as such they belong to the closed-faced
group of TBMs.

Except for mechanical-support TBMs, they all have a cutter head chamber at
the front, isolated from the rearward part of the machine by a bulkhead, in
which a confinement pressure is maintained in order to actively support the
excavation and/or balance the hydrostatic pressure of the ground water.

The face is excavated by a cutter head working in the chamber. The TBM is
jacked forward by rams pushing off the segmental lining erected using an
erector integrated into the machine.

Soft ground TBMs are classified into following types depending upon frontal
support technique they employ:-

a) Mechanical-support TBM/Shield

A mechanical-support TBM has a full-face cutter head which provides face

support by constantly pushing the excavated material ahead of the cutter
head against the surrounding ground.

47
 Its specific field of application is therefore in soft rock and consolidated
soft ground with little or no water pressure.

b) Compressed-air TBM/Shield

A compressed-air TBM can have either a full face cutter head or

excavating arms like those of the different boom-type units. Confinement
is achieved by pressurizing the air in the cutting chamber.

Compressed-air TBMs are particularly suitable for ground of low

permeability with no major discontinuities (i.e. no risk of sudden loss of
air pressure). The ground tunneled must necessarily have an
impermeable layer in the overburden.

Compressed-air TBMs tend to be used to excavate small-diameter

tunnels. Their use is not recommended in circumstances where the
ground at the face is heterogeneous. They should not be used in organic
soil where there is a risk of fire.

c) Slurry shield TBM/Shield

A slurry shield TBM has a full-face cutter head. Support of the face is
accomplished by pressurized slurry; which in most cases is bentonite
suspension.

Slurry shield TBMs are particularly suitable for use in granular soil (sand,
gravel, etc.) and heterogeneous soft ground, though they can also be
used in other terrain, even if it includes hard - rock sections.

There might be clogging and difficulty separating the spoil from the slurry
if there is clay in the soil.

These TBMs can be used in ground with high permeability, but if there is
high water pressure special slurry has to be used to form a watertight
cake on the excavation walls.

d) Earth pressure balance TBM/Shield

An earth pressure balance machine has a full-face cutter head. Support of

the face is achieved by pressurizing the mud, formed of the excavated soil
in the cutter head chamber. In most cases, water and some other
additives (e.g. polymer foams) are added to render the excavated soil
supple.

EPBMs are particularly suitable for soils which, after churning, are likely to
be of a consistency capable of transmitting the pressure in the cutter
head chamber

48
 They can handle ground of quite high permeability, and are also capable
of working in ground with occasional discontinuities requiring localized
confinement.

In addition to above, there are Special Purpose TBMs also. Some of these
are:-

Reaming Boring Machines - allows a tunnel made using a TBM (pilot

tunnel) to be widened (reaming).

Raise Borer - used for shaft excavation which enables the top-to-bottom
reaming of a small diameter pilot tunnel created using a drilling rig.

Mixed Face TBMs – allows tunneling under mixed face conditions.

Multi-Mode TBMs – can operate in different modes with appropriate

modifications to configuration & support techniques.

Selection of TBM: Careful and comprehensive analysis should be made to

select proper machine for tunneling taking into considerations its
reliability, safety, cost efficiency and the working conditions. In particular,
the following factors should be analyzed:

 Suitability to the anticipated geological conditions

 Applicability of supplementary supporting methods, if necessary
 Tunnel alignment and length
 Availability of spaces necessary for auxiliary facilities behind the
machine and around the access tunnels
 Safety of tunneling and other related works.

49
 Chapter 5: NATM

1.1 Background:

The New Austrian Tunnelling Method (NATM) was developed by the Austrians
Ladislaus von Rabcewicz, Leopold Müller and Franz Pacher in the 1950s. The
name was introduced in 1962 (Rabcewicz 1963) to distinguish it from the
‘Austrian Tunnelling Method’, today referred to as the ‘Old Austrian
Tunnelling Method’.

Although Rabcewicz, Müller and Pacher used techniques and knowledge

which were already well known, this was the first time these techniques had
been put together in a new and almost revolutionary tunnelling method.
Instead of fighting the overburden by a thick lining they acknowledged that
the ground, not the lining is the main support of the tunnel. Consequently
they reduced the lining thickness radically using sprayed concrete instead of
the brick lining, which was common at the time. This gave the benefit of a
tight and firm coupling between the lining and the ground; whereas the brick
lining left a space between the support and the surrounding ground.

Loosening pressure was conventionally considered to be the main active

force to be reckoned with in tunnel design. NATM approach emphasized the
importance of avoiding loosening almost entirely. Whereas the earlier
methods of temporary support were bound to cause loosening and voids by
yielding of the different parts of the supporting structure, a thin layer of
shotcrete together with a suitable system of rock bolting applied to the rock
face immediately after blasting entirely prevents loosening and reduces
decompression to a certain degree, transforming the surrounding rock into a
self-supporting arch. A layer of shotcrete with a thickness of only 15cm
applied to a tunnel of 10 m diameter can safely carry a load of 45 tons/m2
corresponding to a burden of 23 m of rock.

Furthermore, it was important that the sprayed concrete lining (SCL) was
supported by systematic anchoring. Rabcewicz, Müller and Pacher used a
flexible approach with respect to the excavation sequence and amount of
support. They observed the reaction of the ground as a result of the
tunneling process and used this information to determine the required
support and construction sequences. The calculation techniques available at
that time could not confirm the stability of this thin lining. Therefore, they
used displacement monitoring to prove the efficiency of their support.

1.2 Definition of NATM:

Austrian National Committee defines NATM as “a concept which makes the

ground (rock or soil) surrounding the void a supporting construction element
through the activation of a ground supporting arch.”

50
 Unfortunately, this definition did not prove to be unique to NATM since nearly
every excavation method tries to preserve the supporting ability of the
ground. Rokahr (1995) gave a definition which summarizes the original
intention of Rabcewicz, Müller and Pacher and makes it easy to distinguish
the NATM from other tunnelling methods: ‘NATM is a support method to
stabilize the tunnel perimeter by means of sprayed concrete, anchors and
other support, and uses monitoring to control stability”.

Another useful definition as given by H. Lauffer is “NATM is a tunnelling

method in which excavation and support procedures, as well as measures to
improve the ground-which should be distorted as low as possible,- depend on
observations of deformation and are continuously adjusted to the
encountered conditions”.

1.3 Principles of NATM

The main principles of NATM are:-

 The main load-bearing component of the tunnel is the surrounding rock

mass. The sprayed concrete has only a secondary supporting function.
Maintain strength of the rock mass and avoid detrimental loosening by
careful excavation and by immediate application of support and
strengthening means. Shotcrete and rock bolts applied close to the
excavation face help to maintain the integrity of the rock mass.

 The support must not be installed too early or too late. It should not be
too stiff or too weak.

The level of deformation in the ground should be:

 on the one hand kept small so that the ground does not lose
more of its initial stability than unavoidable and;
 on the other hand must be large enough in order to activate the
support of the ground as a closed arch and to optimize the
usage of the support measures and the excavation.

 The tunnel is to be seen as a composite system consisting of the ground,

and the support and stabilizing measures, e.g. sprayed concrete, anchors,
steel ribs and similar.

 Rounded tunnel shape: avoid stress concentrations in corners where

progressive failure mechanisms start.

 Flexible thin lining: The primary support shall be thin-walled in order to

minimize bending moments and to facilitate the stress rearrangement
process without exposing the lining to unfavourable sectional forces.
Additional support requirement shall not be added by increasing lining
thickness but by bolting. The lining shall be in full contact with the
exposed rock. Shotcrete fulfills this requirement.

51
  The closing of the ring is important, i.e. the total periphery including the
invert must be applied with shotcrete.

 In situ measurements: Observation of tunnel behaviour during

construction is an integral part of NATM. The choice of support and
construction sequence is made on the basis of monitoring of tunnel
behavior. Observational method requires:-

 Determination of acceptable limits for the behaviour of a construction

 Verification that these limits will (with sufficient probability) not be
exceeded
 Establishing a monitoring programme that gives sufficient warning of
whether these limits are kept
 Providing measures for the case that these limits are exceeded.

1.4 Construction Sequence:

The construction process is as follows:

 Excavation: The tunnel advance can be achieved using blasting, a partial

face boring machine or simply using an excavator, depending on the
ground conditions. Generally, the advancement is spatially and timely
staggered in the heading, benching and invert.
 Sealing the exposed ground if necessary.
 Mucking.
 Installation of lattice girders or mesh reinforcement, and application of
shotcrete. Depending on the quality of the ground the support might be
installed first before the spoil is removed.
 Potential installation of a second layer of reinforcement and application of
shotcrete.
 Installation of anchors.
 Construction of inner lining.

1.5 Excavation & Supporting sequence is illustrated below:-

Excavating a length of tunnel, Applying layer of shotcrete on

(here with a roadheader) reinforcement mesh

52
 Primary lining applied to whole cavity, View of Final lining applied.
which remains under observation

Track structure laid

1.6 Limitation:

NATM assumes that the ground has sufficient stand-up time itself for the
construction cycle. In order to use NATM, the ground has to be capable of
supporting itself over the length of each advance section, which means that
the ground must have a stand-up time. The limit of this construction
technique is reached when the stand-up time of the ground has to be
improved by artificial measures, such as freezing or grout injection.

1.7 Pre-requisites for NATM

 Balanced Contract Structure:- providing for equitable risk sharing &

flexible approach as per varying technical requirements.

53
  Qualified Personnel: particularly for ensuring quality of shotcrete, rock
bolts.
 Better Site Management: for –
 Coping with unseen events
 Proper application of the observational method
 Elimination of human errors
 Continuous Monitoring of geology:- by qualified & experienced geologists-
for interpretation of exploration data & keeping thorough geological
record.

1.8 Advantages of NATM:

 Flexibility to adopt different excavation geometries and very large cross

sections.
 Lower cost requirements for the tunnel equipment at the beginning of the
project.
 Flexibility to install additional support measures, rock bolts, dowels, steel
ribs if required.
 Easy to install a waterproof membrane.
 Flexibility to monitor deformation and stress redistribution so that
necessary precautions can be taken.

2.0 NMT

A variant of NATM using steel-fiber reinforced shotcrete (SFRS) instead of

mesh-reinforced concrete is referred to as the Norwegian Method of
Tunnelling (NMT).

54
 Chapter 6:Tunnel Design Methods

1.0 Tunnel Design

Tunnel design must achieve functionality, stability, and safety of the tunnel
opening during and after construction and for as long as the underground
structure is expected to function. Tunnel design includes design of initial
ground support as well as permanent support system.

There are two basic methodologies employed in selecting initial ground

support, and one or both of these approaches may be used.

 Empirical Approach: constructed from experience records of

satisfactory past performance.

 Analytical and/or numerical approach: based on theoretical or semi

theoretical analysis and/or involving a fundamental approach, with
study/investigation of potential modes of failure and a selection or design
of components to resist these modes of failure.

Tunnel design approaches for non-NATM & NATM are discussed below:-

1.1 Non-NATM

(A) Empirical Approach for Selection of Initial Support for rocks

In past centuries, ground support was always selected empirically. The miner
estimated, based on his experience, what timbering was required, and if the
timbering failed it was rebuilt stronger. Written rules for selecting ground
support were first formulated by Terzaghi (1946). The development of the
RQD as a means to describe the character or quality of the rock mass led to
correlations between RQD and Terzaghi’s rock loads. This development also
led to independent ground support recommendations based on RQD. The
RQD is also used in two other rock mass characterization schemes used for
initial ground support selection, the Geo-mechanics Classification: Rock Mass
Rating (RMR), Bieniawski 1979), and the Norwegian Geotechnical Institute’s
Q-system (Barton, Lien, and Lunde 1974).

55
1.1.1 Terzaghi’s rock loads & support recommendations

Terzaghi’s qualitative classification of rock mass/conditions is tabulated

below:-

Terzaghi’s Rock Mass Classification

Rock Description
Condition
Intact rock Contains neither joints nor hair cracks. Hence, if it breaks, it
breaks across sound rock. On account of the injury to the
rock due to blasting, spalls may drop off the roof several
hours or days after blasting. This is known as a spalling
condition. Hard, intact rock may also be encountered in the
popping condition involving the spontaneous and violent
detachment of rock slabs from the sides or roof.
Stratified rock Consists of individual strata with little or no resistance
against separation along the boundaries between the strata.
The strata may or may not be weakened by transverse
joints. In such rock the spalling condition is quite common.
Moderately Contains joints and hair cracks, but the blocks between
jointed rock joints are locally grown together or so intimately interlocked
that vertical walls do not require lateral support. In rocks of
this type, both spalling and popping conditions may be
encountered.
Blocky and Consists of chemically intact or almost intact rock fragments
seamy rock which are entirely separated from each other and
imperfectly interlocked. In such rock, vertical walls may
require lateral support.
Crushed but Has the character of crusher run. If most or all of the
chemically fragments are as small as fine sand grains and no
intact rock recementation has taken place, crushed rock below the
water table exhibits the properties of a water-bearing sand.
Squeezing Slowly advances into the tunnel without perceptible volume
rock increase. A prerequisite for squeeze is a high percentage of
microscopic and submicroscopic particles of micaceous
minerals or clay minerals with a low swelling capacity.
Swelling rock Advances into the tunnel chiefly on account of expansion.
The capacity to swell seems to be limited to those rocks
that contain clay minerals such as montmorillonite, with a
high swelling capacity.

Terzaghi estimated rock loads acting on roof of tunnel supports for various
rock mass classifications/conditions. He described these loads in terms of the
height of a loosened mass of rock weighing on the support. The height is a
multiple of the width of the tunnel or of the width plus the height.

56
 Terzaghi’s recommendations are tabulated below (giving Rock Load Hp
in feet of rock of support in tunnel with Width B (ft) and Height Ht (ft) at
depth more than 1.5C, Where C = B + Ht) :-

Rock Condition Rock Load Remarks

Hp in feet

1. Hard and Zero Light lining, required only if spalling or

intacta popping occurs.

2. Hard stratified 0 to 0.5B Light support.

or schistoseb
3. Massive 0 to 0.25B Load may change erratically from point
moderately to point.
jointed
4. Moderately 0.25B to No side pressure.
blocky and 0.35C
Seamy
5. Very blocky (0.35 to Little or no side pressures.
and seamy 1.10)C

6. Completely 1.10C Considerable side pressure. Softening

crushed but effect of seepage toward bottom of
chemically tunnel requires either continuous support
intact
for lower end of ribs or circular ribs.

7. Squeezing (1.10 to Heavy side pressure, invert struts

rock, moderate 2.10)C required.
depth
8. Squeezing (2.10 to Circular ribs are recommended.
rock, great 4.50)C
depth
9. Swelling rock Up to 250 Circular ribs required. In extreme cases
feet use yielding support.
irrespective of
value of C
a The roof of the tunnel is assumed to be located below the water table. If it
is located permanently above the water table, the values given for types 4
to 6 can be reduced by 50%.

b Some of the most common rock formations contain layers of shale. In an

un-weathered state real shales are no worse than other stratified rocks.
However, the term shale is often applied to firmly compacted clay sediments
which have not yet acquired the properties of rock. Such so called shale may
behave in the tunnel like squeezing or even swelling rock. If a rock
formation consists of a sequence of horizontal layers of sandstone or

57
 limestone and of immature shale, the excavation of the tunnel is commonly
associated with a gradual compression of the rock on both sides of the
tunnel involving a downward movement of the roof. Furthermore the
relatively low resistance against slippage at the boundaries between the so-
called shale and rock is likely to reduce very considerably the capacity of the
rock located above the roof of bridge. Hence in such rock formations the roof
pressure may be as heavy as in a very blocky and seamy rock.

Terzaghi’s rock load estimates were derived from an experience of tunnels

excavated by blasting methods and supported by steel ribs or timbers.
Ground disturbance and loosening occur due to the blasting prior to
installation of initial ground support, and the timber blocking used with ribs
permits some displacement of the rock mass. As such, Terzaghi’s rock loads
generally should not be used in conjunction with methods of excavation and
support that tend to minimize rock mass disturbance and loosening, such as
excavation with TBM and immediate ground support using shotcrete and rock
bolts.

Today rock tunnels are usually designed considering the interaction between
rock and ground, i.e., the redistribution of stresses into the rock by forming
the rock arch. However, the concept of loads still exists and may be applied
early in a design to “get a handle” on the support requirement. The concept
is to provide support for a height of rock (rock load) that tends to drop out of
the roof of the tunnel (Terzaghi,1946).

2.0 Rock Quality Designation (RQD)

In 1966 Deere and Miller developed the Rock Quality Designation index
(RQD) to provide a systematic method of describing rock mass quality from
the results of drill core logs. Deere described the RQD as the length (as a
percentage of total core length) of intact and sound core pieces that are 4
inches (10 cm) or more in length.

It has been shown that a qualitative relationship exists between the RQD and
the support required for tunnels in rocks. Several proposed methods of using
the RQD for design of rock tunnels have been developed. Support
recommendations (Deere et al., 1967) for tunnels having 6 m (i.e. 20 ft) to
12m (i.e. 40ft) dia are tabulated below:-

58
 Support Recommendations for Tunnels in Rock (6 m to 12 m diam)
based on RQD (after Deere et al. 1970)

Alternative Support Systems

Rock Quality Tunneling Steel sets3 Rockbolts Shotcrete
3
Method
Excellent1 Boring None to ocassional light None to None to ocassional
RQD>90 machine set. ocassional local application
Rock load (0.0–.2)B

Conventional None to ocassional light None to None to ocassional

set. ocassional local application 2
Rock load (0.0–0.3)B to 3 in.

Good1 Boring Ocational light sets to Ocassional None to ocassional

75<RQD<90 machine pattern on 5 to 6 ft to pattern local application 2
center. on 5 to 6ft to 3 in.
Rock load (0.0 to 0.4)B centers

Light sets 5 to 6 ft Pattern, 5

Conventional center. to 6 ft Ocassional local
Rock load(0.3 to 0.6)B centers application 2 to3
in.
Fair Boring Light to medium sets, Pattern, 4 2 to 4 in. crown
50<RQD<75 machine 5 to 6 ft center. to 6 ft
Rock load (0.4 to 1.0)B centers

Light to medium sets, Pattern, 3 4 in. or more

Conventional 4 to 5 ft center. to 5 ft crown and sides
Rock load (0.6 to 1.3)B centers

Poor2 Boring Medium circular sets on Pattern, 4 to 6 in. on crown

25<RQD<50 machine 3 to 4 ft center. Rock 3 to 5 ft and sides.
load (1.0 to 1.6) B center Combine
withbolts.

Conventional Medium to heavy Pattern, 2 6 in. or more on

circular sets, 2 to 4 ft to 4 ft crown and sides.
center. center Combine with
Rock load (1.3 to 2.0)B bolts.

Very poor3 Boring Medium to heavy Pattern, 6 in. or more on

RQD<25 machine circular sets on 2 ft 2 to 3 ft whole selection.
(Excluding center. center Combine with
squeezing or Rock load (1.6 to 2.2)B medium sets.

59
 swelling
ground)

Conventional Heavy circular sets on Pattern, 6 in. or more on

2 ft center. 3 ft center whole selection.
Rock load (1.6 to 2.2)B Combine with
medium sets.
Very poor3 Boring Very heavy circular sets Pattern, 6 in. or more on
(squeezing or machine on 2 ft center. 2 to 3 ft whole section.
swelling) Rock load up to 250 ft. center Combine with
heavy sets.
Conventional Very heavy circular sets Pattern, 6 in. or more on
on 2 ft center. Rock 2 to 3 ft whole section.
load up to 250 ft. center Combine with
heavy sets.

Notes:-
1
In good and excelent rock, the support requirement will be, in general,
minimal but will be dependent upon joint geometry, tunnel diameter, and
relative orientations of joints and tunnel.
2
Lagging requirements will usually be zero in excellent and will range from up
to 25 percent in good rock to 100 percent in very poor rock.
3
Mesh requirements usually will be zero in excellent rock and will range from
ocassional mesh (or strip) in good rock to 100 percent mesh in very poor
rock.
4
B = tunnel width.

The major use of the RQD in modern tunnel design is as a major factor in
the Q or RMR rock mass classification systems.

3.0 Support Selection based on Rock Mass Rating (RMR) System:

The geomechanics classification also known as Rock Mass Rating (RMR)

was developed by Bieniawski (1973, 1974, 1979).

The following six parameters are used to classify a rock mass using the RMR
system:
1. Strength of Intact Rock Material ( Point Load Strength Index or
Uniaxial compressive strength of rock material)
2. Rock Quality Designation (RQD).
3. Spacing of discontinuities.
4. Condition of discontinuities.
5. Groundwater conditions.
6. Orientation of discontinuities.

60
 Ratings for each of the six parameters listed above are summed to give a
value of RMR

In applying this classification system, the rock mass is divided into a number
of structural regions and each region is classified separately. The boundaries
of the structural regions usually coincide with a major structural feature such
as a fault or with a change in rock type. In some cases, significant changes in
discontinuity spacing or characteristics, within the same rock type, may
necessitate the division of the rock mass into a number of small structural
regions.

IS Code 13365 Part 1 may be referred to for more details of this rating
system.

Recommendations for excavation and support of 10 m Span Rock Tunnels in

accordance with the RMR System are tabulated below:

Rock mass Excavation Rock bolts (20 Shotcrete Steel sets

class mm diameter,
fully grouted)
I–very good Full face Generally no support required except spot bolting
rock 3 m advance
RMR: 81-100
II – Good Full face, Locally, bolts in 50 mm in None
rock 1-1.5m advance. crown 3 m long, crown
RMR: 61-80 Complete support 20 m spaced 2.5 m where
from face with occasional required
wiremesh
III – Fair rock Top heading and bench Systematic bolts 50-100 mm None
RMR: 41-60 1.5-3 m advance in top 4m long, spaced in crown
heading.Commence 1.5-2 m in crown and 30 mm
support after each andwalls with in sides
blast. Complete support wire mesh in
10 m from face. crown.
IV – Poor Top heading and bench Systematic bolts 100-150 Light to medium
rock 1.0-1.5 m advance in 4-5 m long, mm in ribs spaced 1.5
RMR: 21-40 top heading. Install spaced 1-1.5 m in crown and m where
support concurrently crown and walls 100 mm in required
with excavation, 10 m with wire mesh. sides
from face.
V – very poor Multiple drifts. Systematic bolts 150-200 Medium to
rock 0.5-1.5 m advance in 5-6 m long, mm in heavy ribs
RMR: < 20 top heading. Install spaced 1-1.5 m in crown, 150 spaced steel
support concurrently crown and walls mm in lagging and
with excavation. with wire mesh. sides, and forepoling if
Shotcrete as soon as Bolt invert. 50 mm on required.
possible after blasting. face Close invert.

61
4.0 Support Selection based on Q-System of rock mass classification:

The NGI Q-System (Barton, Lien and Lunde 1974) is generally considered the
most elaborate and the most detailed rock mass classification system for
ground support in underground works. The value of the rock quality index Q
is determined by

Q= (RQD/J n) (J r/J a) (J w/SRF)

where:-
RQD= Rock Quality Designation
Jn = joint set number
Jr = joint roughness number
Ja = joint alteration number
JW= joint water reduction factor
SRF = stress reduction factor

Numerical range of the six parameters used in calculation of Q value is large,

and the combined effect of their use results in Q Value having an extremely
large range (approx. from 0.001 to 1000). Accordingly, the Q System
accommodates the entire spectrum of rock mass conditions ranging from
sound, un-jointed rock to heavy squeezing ground.

A high Q-value means good stability, whereas low values indicate poor
stability. The Q-values together with the span width or height of walls and
safety requirements are used as a basis for an evaluation of permanent
support.

Implementation of Q system is done through calculating Q and effective

span. The effective span is Barton’s method of applying a risk/safety factor to
the application. It is obtained by dividing the actual span by Excavation
Support Ratio (ESR). A lower ESR provides a higher degree of safety. An ESR
of 1.0 is used for civil work projects including railway tunnels.

Standard literature may be referred to for more details of the rock quality
rating for Q-System and its application for design purposes. One good
document on different Rock Mass Classifications &their applications for tunnel
design is available at following URL:
http://www.rocscience.com/hoek/corner/3_Rock_mass_classification.pdf

5.0 Empirical Approach for Selection of Initial Support for soft ground

Anticipated ground behavior in soft ground tunnels was first defined by

Terzaghi (1950) by means of the Tunnel man’s Ground Classification, a
classification system of the reaction of soil to tunneling operation. Terzaghi
described the representative soil types and the predicted behavior of these
ground types to the tunneling construction methods in use in 1950s. Heur
(1974) modified the Tunnel man’s Ground Classification, as shown in table

62
 below to present the classification system in engineering terms that reflect
current terminology and usage.
Table
Classification Behavior Typical Soil Types
Firm Heading can be advanced Loess above water table; hard clay, marl,
without initial support, cemented sand and gravel when not highly
and final lining can be overstressed.
constructed before ground
starts to move.
Raveling Slow Chunks or flakes of Residual soils or sand with small amounts of
raveling material begin to drop out binder may be fast raveling below the water
of the arch or walls tale, slow raveling above. Stiff fissured clays
sometimes after the may be slow or fast raveling depending upon
ground has been exposed, degree of overstress.
due to loosening or to
over-stress and “brittle”
fracture (ground
separates or breaks along
distinct surfaces, opposed
to squeezing ground).
In fast raveling ground,
the process starts within a
Fast few minutes, otherwise
raveling the ground is slow
raveling.

Squeezing Ground squeezes or Ground with low frictional strength. Rate of

extrudes plastically into squeeze depends on degree of overstress.
tunnel, without visible Occurs at shallow to medium depth in clay of
fracturing or loss of very soft to medium consistency. Stiff to hard
continuity, and without clay under high cover may move in
perceptible increase in combination of raveling at excavation surface
water content. Ductile, and squeezing at depth behind surface.
plastic yield and flow due
to overstress.
Running Cohesive Granular materials Clean, dry granular materials. Apparent
running without cohesion are cohesion in moist sand, or weak cementation
unstable at a slope in any granular soil, may allow the material to
greater than their angle stand for a brief period of raveling before it
of repose (approx 30°- breaks down and runs. Such behavioris
Running 35°). When exposed at cohesive-running.
steeper slopes they run
like granulated sugar or
dune sand until the slope
flattens to the angle of
repose.
Flowing A mixture of soil and Below the water table in silt, sand or gravel
water flows into the without enough clay content to give
tunnel like a viscous fluid. significant cohesion and plasticity. May also

63
 The material can enter occur in highly sensitive clay when such
the tunnel from the invert material is disturbed.
as well as from the face,
crown, and walls, and can
flow for great distances,
completely filling the
tunnel in some cases.
Swelling Ground absorbs water, Highly pre-consolidated clay with plasticity
increases in volume, and index in excess of about 30, generally
expands slowly into the containing significant percentages of
tunnel. montmorillonite.
* Modified by Heuer (1974) from Terzaghi (1950)

Anticipated ground behavior has been further expanded by various

researchers/authors for various soil conditions (clays to silty sands, cohesive soils,
silty sands, sands, gravels) above/below the water table. Standard technical
literature may be referred to for more details in this regard.

A simplified system of determining the load on the initial support for circular and
horseshoe tunnels in soft ground is tabulated below The loads are patterned after
Terzaghi’s original recommendations (1950) but have been simplified. In all cases,
it is important that the experience and judgment of the engineer also be applied to
the load selection.

Table :Initial Support Loads for Tunnels in Soft Ground

Geology Circular Tunnel Horseshoe Tunnel

Running ground Lessor of full Lessor of full overburden
overburden or 1.0 B or 2.0 B
Flowing ground in air Lessor of full Lessor of full overburden
free overburden or 2.0 B or 4.0 B
Raveling ground
 Above water Same as running Same as running ground
table ground Same as flowing ground
 Below water Same as flowing
table ground

Squeezing ground Depth to tunnel Depth to tunnel springline

springline
Swelling ground Same as raveling Same as raveling ground
ground

6.0 Limitations in the use of empirical ground support selection systems

a) The empirical methods of ground support selection provide a means to

select a ground support scheme based on facts that can be determined

64
 from explorations, observations, and testing. They are far from perfect
and can sometimes lead to the selection of inadequate ground support. It
is therefore necessary to examine the available rock mass information to
determine if there are any applicable failure modes not addressed by the
empirical systems.

b) A major flaw of all the empirical systems is that they lead the user
directly from the geologic characterization of the rock mass to a
recommended ground support without the consideration of possible failure
modes. A number of potential modes of failure are not covered by some
or all of the empirical methods and must be considered independently,
including the following:

 Failure due to weathering or deterioration of the rock mass.

 Failure caused by moving water (erosion, dissolution, excessive
leakage, etc.).
 Failure due to corrosion of ground support components.
 Failure due to squeezing and swelling conditions.
 Failure due to overstress in massive rock.

c) The empirical systems are largely based on blasted tunnels. System

recommendations should be reinterpreted based on current methods of
excavation. Similarly, new ground support methods and components must
be considered.

(B) Analytical and Numerical Approach: This approach makes use of various
theoretical, Semi-theoretical & numerical Methods to design individual
support components like rockbolts, shotcrete, steel ribs, etc. It may also
involve a fundamental approach, with study/investigation of potential modes
of failure and a selection or design of components to resist these modes of
failure (using methods like finite elements, finite differences etc.).

65
1.2 Design of tunnels for NATM : - The design process for NATM tunnels is
represented in figure below:-
CONCEPT

It can be seen that design can follow either the “Empirical” approach or the
“Analytical” Approach.

Empirical Approach:
and support installation sequencing frequently associated with NATM tunnels
depending on the basic types of ground encountered, i.e. rock and soft
ground respectively.

66
 Elements of Commonly Used Excavation and Support Classes (ESC) in
Rock

Grou Excavatio Rock Initial Installatio Pre- Support Remarks

nd n Reinforce Shotcrete n Location Support Installati
Mass Sequence ment Lining on
Quali influence
ty - s
Rock progress
Intact Full face Spot Patches to seal Typically None No
Rock or large bolting surface in several
top (fully localized rounds
heading & grouted fractured areas behind
bench dowels, face or
swellex(R) directly
) near face
to secure
isolated
blocks,
slabs/wed
ges
Stratif Top Systemati Thin shell (fibre Two to None No or
ied heading & c doweling reinforced) three eventually
Rock bench or bolting typically 4in. rounds
in crown (100 mm) to behind
considerin bridge between face
g strata rock
orientation reinforcement in
(fully top heading,
grouted alternatively
dowels, chain link mesh;
swellex(R) installed with the
, rock rock
bolts) reinforcement.
Moder Top Systemati Systematic shell One to Locally to Yes
ately heading & c doweling with two limit over
Jointe bench or bolting reinforcement rounds break
d in top (welded wire behind
Rock heading fabric or fibres) face
considerin in top heading
g joint and potentially
spacing bench;
(fully dependent on
grouted tunnel size
dowels, thickness of 6 in.
swellex, (150 mm) to 8
rock bolts) in. (200 mm);
installed with the
rock
reinforcement.

67
Block Top Systemati Systematic shell At the Systema- Yes
y and heading & c doweling with face or tic spiling
seam bench or bolting reinforcement maximum in tunnel
y in top (welded wire one round roof or
Rock heading & fabric or fibres) behind parts of it
bench in top heading face
considerin and bench;
g joint depending on
spacing tunnel size
thickness 8 in.
(200 mm) to 12
in. (300 mm)
Crush Top N/A Systematic shell After each Sysstematic Support If water
ed but heading, with round grouted installatio is
chemi bench, reinforcement pipe spiling n dictates present,
cally invert (welded wire or pipe progress ground
intact fabric or fibres) arch water
rock and ring closure canopy draw
in invert; down or
dependent on ground
tunnel size improve
thickness 12 in. ment is
(300 mm) and required
more; for initial
stabilization and
to prevent
desiccation, a
layer of
flashcrete may
be required
Squee Top Systemati Systematic shell After each Sysstematic Support -
zing heading, c dowling with round grouted installatio
Rock bench, or bolting reinforcement pipe spiling n dictates
invert in top (welded wire or pipe progress
heading & fabric or fibres) arch
bench and ring closure canopy
considerin in invert;
g joint dependent on
spacing; tunnel size
extended thickness 12 in.
length (300 mm) and
more; potential
use for yield
elements; for
initial
stabilization and
to prevent
desiccation, a
layer of

68
 flashcrete may
be required
Swelli Top Systemati Systematic shell After each Sysstematic Support Depend
ng heading, c dowling with round grouted installatio ed
rock bench, or bolting reinforcement pipe spiling n dictates invert
invert in top (welded wire or pipe progress foradditi
heading & fabric or fibres) arch onal
bench and ring closure canopy curvatur
considerin in invert; may be e
g joint dependent on required
spacing; tunnel size depending
extended thickness 12 in. on degree
length (300 mm) and of
more; potential fracturing
use for yield
elements

Table Elements of Commonly Used Soft Ground Excavation and

Support Classes (ESC) in Soft Ground

Ground Excavation Initial Installation Pre- Support Remar

Mass Sequence Shotcrete Location Support Installati ks
Quality-Soil Lining on
Stiff/hard Top heading, Systematic Installation of Typically Support Overall
cohesive soil bench & reinforced shotcrete none; installation sufficien
above invert; (welded wire support locally dictates t stand-
groundwater dependent fabric or immediately spiling to progress up time
table on tunnel fibres) shell after excavation limit over- to intall
size, further with full ring in each round. break support
sub-divisions closure in Early support without
into drifts invert; ring closure pre-
may be dependent required. Either support
required on tunnel temporary ring or
size 6 in. closure (e.g. ground
(150 mm) to temporary top modifica
16 in. (400 heading invert) tion
mm) typical, or final ring
for initial closure to be
stabilization installed within
and to one tunnel
prevent diameter
desiccation, behind
a layer of excavation face
flashcrete
may be
required
Stiff/hard Top heading, Systematic Installation of Typically Support Sufficien

69
cohesive soil bench & reinforced shotcrete none; installation t stand-
– above invert; (welded wire support locally pre- dictates up time
groundwater dependent fabric or immediately spiling to progress to intall
table on ground fibres) shell after excavation limit over- support
strength, with full ring in each round. break without
smaller closure in Early support pre-
drifts invert; ring closure support
required dependent required. Either or
than above on tunnel temporary ring ground
size 6 in. closure (e.g. improve
(150 mm) to temporary top ment;
16 in. (400 heading invert) depende
mm) typical, or final ring nt on
for initial closure to be water
stabilization installed within saturatio
and to less than one n,
prevent tunnel diameter swelling
desiecation, behind or
a layer of excavation squeezin
flashcrete face; typically g can
may be earlier ring occur
required; closure
frequently requireed than
more invert above
curvature
than above
Well Top heading, Systematic Installation of Frequently Support Stand-
consolidated bench reinforced shotcrete systematic installation up time
non-cohesive &invert; (welded wire support pre- dictates insufficie
soil – above dependent fabric or immediately support progress nt to
groundwater on tunnel fibres) shell after excavation required by safety
table size, further with full ring in each round. ground install
sub-divisions closure in Early support pipe spiling support
into drifts invert; ring closure or ground without
may be dependent required. Either pipe arch pre-
required on tunnel temporary ring canopy, support
size 6 in. closure (e.g. alternativel or
(150 mm) to temporary top y ground ground
16 in. (400 heading invert) improveme improve
mm) typical, or final ring nt ment
for initial closure to be
stabilization installed within
and to less than one
prevent tunnel diameter
desiccation, behind
a layer of excavation face
flashcrete is
required
Well Top heading, Systematic Installation of Frequently Support Stand-
consolidated bench & reinforced shortcrete up time
support

70
Analytical & Numerical Approach:

The following steps typically are used in the analyses to model the
construction process:

• Excavation of the ground.

• Establishment of steady state flow conditions.
• Relaxation of the ground to represent deformations in advance of support.
• Installation of the primary lining.
• Analysis of the model and solving to equilibrium.
• Installation of the secondary lining.
• Analysis of the model and solving to equilibrium

The results obtained from the analysis are checked to confirm their
acceptability. In addition to the static loadings, the performance of the
secondary lining is checked for dynamic loading.

Numerical modeling is aperticulary useful tool for design of sequentially

excavated, shotcrete-lined tunnels in soft ground. For numerical modeling of
tunnel linings in soft ground, software such as Flac or Plaxis may be used. It
is necessary to know the theory behind the software and to correlate the
analysis with tunnel behavior in the field.

71
 Chapter 7: Structural Design Issues: Tunnel Lining

1. Design Philosophy

Tunnel Lining refers to systems installed after excavation of tunnel to provide

permanent support and durable, maintainable long term surface finishes. Various
types of systems employed for the purpose are as under:

(i) Shotcrete
(ii) Cast in place concrete
(iii) Precast segments
(iv) Lattice Girder and rolled steel sets.
(v) Ribs and Laggings.

These systems are briefly described hereinafter.

1.1 Shotcrete

It is also used some times as permanent lining. Permanent shotcrete linings are
normally built in layers with surface layer containing wire mesh to provide long
term ductility. In case, toughness and ductility are desirable, shotcrete reinforced
with randomly oriented steel/synthetic fibres may be used as alternative.
Occasionally, structural plastic fibres are used in lieu of steel fibres when
shotcrete is expected to undergo high deformation and ductility post-cracking is of
importance.

Shotcrete provides immediate support after excavation by filling small openings,

cracks and fissures. This reduces potential relative movement of rock bodies or
soil particles and limits loosening of exposed ground surrounding tunnel.

The adhesion of shotcrete depends on condition of ground surface, dampness

and presence of water and composition of shotcrete and pressure of shotcrete.
Generally rougher ground surface provides better adhesion. Dry rock surface
have to be adequately dampened prior to application. Dusty or flaky surfaces,
water inflow or water film on surface reduce adhesion. Modern admixtures can
improve adhesion of shotcrete significantly to reduce rebound, however, these
should be used judiciously to avoid its ill effect e.g. accumulation around
reinforcement bars, voids etc.

72
1.1.1 Initial Shotcrete Lining:

Initial shotcrete lining typically consists of 100 to 400mm thick shotcrete layer
mainly depending on the ground conditions and size of the tunnel opening, and
provides support pressure to the ground. It is also referred to as shotcrete lining.
A shotcrete ring can carry significant ground loads although the shotcrete lining
forms a rather flexible support system. This is the case where the shotcrete lining
is expected to undergo high deformations and hence ductility post cracking is of
importance. By deforming, it enables the inherent strength and self-supporting
properties of the ground to be mobilized as well to share and re-distribute stresses
between the lining and ground. This process generates subgrade reaction of the
ground that provides support for the lining. From the ground support point of view
the design of the shotcrete lining is governed by the support requirements, i.e.,
the amount of ground deformations allowed and ground loads expected as well as
economical aspects. The earlier the sprayed concrete gains strength the more the
support restrains ground deformation. However, by increasing stiffness the
support system increasingly attracts loads. It depends on the ground conditions
and local requirements how stiff or flexible the support system has to be and thus
what early strength requirements, thickness and reinforcement should be
specified.

In shallow tunnel applications and beneath surface structures that are sensitive to
deformations such as buildings, ground deformations and consequently surface
settlements have to be kept within acceptable limits. The advantage of the
mobilization of the self-supporting capacity of the ground can therefore be only
taken into account to a very limited extent. Here, early strength of the shotcrete is
required to gain early stiffness of the support to limit ground deflections. Under
these conditions the shotcrete lining takes on significant ground loads at an early
stage however, in a generally low stress environment due to the shallow
overburden. Early strength can be achieved with admixtures and modern types of
cement.

In contrast, for tunnels under high overburden, the prevention of ground

deformation and surface settlement plays a secondary role. By allowing the
ground to deflect (without over-straining it) the ground’s self-supporting capability,
mainly shear strength, is mobilized. Consequently, the ground loads acting upon
the shotcrete lining can be limited significantly because the ground assumes a
part of the support function and a portion of the ground loads is dissipated before
the initial support is loaded. For rock tunnels under high cover, early strength is
not a necessity but final strength of the entire system(including rock) is of
importance.

73
 Rock reinforcement installed in rock tunnels augments the strength of the
surrounding ground, controls deformation and limits the ground loads acting upon
the shotcrete initial lining. Shotcrete support and rock reinforcement are designed
to form an integrated support system in view of the excavation and support
sequence. The design engineer must define the requirements for the support
system based on thorough review of the ground response anticipated.

The effect of the shotcrete is heavily dependent on the radial and tangential
subgrade reaction generated by the surrounding ground. Therefore, shape,
shotcrete thickness and installation time have to be designed in accordance with
the ground conditions and the capacities of the surrounding ground and the
support system. Site personnel should assess the support requirements and, if
necessary, adjust the designed support system based on observations in the field.
Notwithstanding the need for reaction to site conditions, the designer should
always be party to the decision making process prior to changing any support
system on site. The design intent and philosophy must be taken into consideration
when adjustments of the support system are made.

Friction between the ground and the sprayed concrete lining (tangential subgrade
reaction) is paramount for the support system. This friction reduces differential
movement of ground particles at the ground surface and contributes to the
ground-structure interaction. Even the shotcrete arch not forming a closed ring
provides substantial support to the ground, if tight contact between the sprayed
concrete and the ground is maintained.

The requirement for a ring closure, be it temporary or permanent, is governed by

the size of the underground opening and the prevailing ground conditions. In a
good quality rock mass, no ring closure is required. In low quality ground (weak
rock and soil), it has been reportedly proven that the time of support application
after excavation, length of excavation round and time lag between the excavation
of the top heading and the invert closure rules the ground and lining deflection. To
reduce ground deflection and the potential for ground /lining failure, the
excavation and support sequence must be designed such that an early ring
closure of the shotcrete support in soft ground is achieved. Also the timely
(immediately after excavation) installation of the shotcrete support members is of
utmost importance.
An importance aspect of shotcrete linings is the design and execution of
construction joints. These joints are located at the contact between shotcrete
applications in longitudinal and circumferential directions between the initial lining
shells of the individual excavation rounds and drifts. An appropriate location and
shape as well as connection of the reinforcement through the longitudinal joints is
of utmost importance for the integrity and capacity of the support system.

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 Longitudinal joints have to be oriented radially, whereas circumferential joints
should be kept as rough as possible. Splice bars/clips and sufficient lapping of
reinforcement welded wire fabric maintain the continuity of the reinforcement
across the joints. Rebound, excess water, dust or other foreign material must be
removed from shotcrete surface against which fresh concrete will be sprayed. The
number of construction joints should be kept to a minimum.

In case of ground water ingress, the ground water has to be collected and drained
away. Any build-up of groundwater pressure behind the shotcrete lining should be
avoided because increased ground water pressure in joints and pores reduces the
shear strength in the ground, undue loads may be shed onto the shotcrete lining
(unless it is designed for that, which is unusual for initial shotcrete linings);
softening of the ground behind the lining; increased leaching of shotcrete and
shotcrete shell detachment from the ground.

1.1.2 Final Shotcrete Lining:

Shotcrete as a final lining is typically utilized in combination with the initial

shotcrete supports in NATM applications when the following conditions are
encountered:

 The tunnels are relatively short in length and the cross section is relatively
large and therefore investment in formwork is not warranted, i.e. tunnel of less
than 250m in length and larger than about 12m in spring line diameter.
 The access is difficult and staging of formwork installation and concrete
delivery is problematic.
 The tunnel geometry is complex and customized formwork would be required.
Tunnel intersections, as well as bifurcations qualify in this area.

When shotcrete is utilized as a final lining in dual shotcrete lining applications, it

will be applied against a waterproofing membrane. The lining thickness will be
generally 200 to 300 mm or more and its application must be carried out in layers
with a time lag between layer applications to allow for shotcrete setting and
hardening. To ensure a final lining to behave close to monolithic from structural
point of view, it is important to limit the time lag between layer applications and
ensure that the shotcrete surface to which the next layer is applied is clean and
free of any dust or dirt films that could create a de-bonding feature between the
individual layers. It is typical to limit the application time lag between the layers to
24 hours. Shotcrete final linings are applied onto a carrier system that is
composed of lattice girders and welded wire fabric mounted to lattice girders
toward the waterproofing membrane side. This carrier system also acts fully or
partially as structural reinforcement of the finished lining. The remainder of the

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 required structural reinforcing may be accomplished by rebars or mats or by steel
or plastic fibers. The final shotcrete layer allows for the addition of micro poly
propylene (PP) fibres that enhance fire resistance of the final lining.

Unlike the hydrostatic pressure of cast-in-place concrete during installation the

shotcrete application does not develop pressures against the waterproofing
membrane and the initial lining and therefore one must ensure that any gaps
between water proofing system and initial shotcrete lining and final shotcrete
lining be filled with contact grout. As in final lining applications, contact grout is
accomplished with cementitious grouts but the grout requirements are much
higher. To ensure a proper grouting around the entire lining circumference it is
customary to use longitudinal grout hoses arranged radially around the perimeter.

Major factor that will influence the quality of the shotcrete final lining application is
workmanship. While the skill of the shotcrete applying nozzlemen (by hand or
robot) is at the core of this workmanship, it is important to address all aspects of
the shotcreting process in a method statement. This method statement becomes
the basis for the application procedures, and the applicator’s and the supervisor’s
Quality Assurance/Quality Control (QA/QC) program. Minimum requirements to
be addressed in the method statement are as follows:

 Execution of Work (Installation of Reinforcement, Sequence of Operations,

Spray Sections, Time Lag)
 Survey Control and Survey Method
 Mix Design and Specifications
 QA/QC Procedures and Forms
 Testing (Type and Frequency)
 Qualifications of Personnel
 Grouting Procedures

General trends in tunneling indicate that the application of shotcrete for final
linings present a viable alternative to traditional cast-in-place concrete
construction. The shotcrete lining system fulfills cast-in-place concrete structural
requirements. Design and engineering, as well as application procedures, can be
planned such as to provide a high quality product. Excellence is needed in the
application itself and must go hand-in-hand with quality assurance during
application.

1.1.3 Shotcrete Analysis:

By its capacity to accept shear and bending and its bond to rock surface,
shotcrete prevents displacement of blocks of rock that can potentially fall. It can
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 also act as shell and accept radial loads. It is possible to analyze these modes of
failure only if the loads and boundary conditions are known. Various theories of
analysis provides only a crude approximation of stresses in shotcrete. When
shotcrete is used in NATM, computer analysis can be used to reproduce
construction sequence, including the effect of variations of shotcrete modules and
strength with time.

1.2 Cast in Place Concrete Lining:

These are generally installed some time after the initial ground support. These
can be used in both soft ground and hard rock tunnels and can be constructed of
either reinforced or plain concrete. While the lining may generally remain
unreinforced, structural design considerations and design criteria will dictate the
need and amount of reinforcement.

Flexible membrane based water proofing is advantageous in unreinforced lining

as lack of bond reduces shrinkage cracking in final lining.

To ensure contact between the initial and final linings, contact grouting is
performed as early as final linings have achieved its 28 days strength. This
ensures contact between initial and final tunnel support and any deterioration or
weakening of initial support will lead to an increased loading of the final support by
the increment not being supported by initial lining. The loads can be directly
transformed radially due to direct contact.

Cast in place final lining pour length is normally restricted to limit surface cracking
and is mandatorily followed in unreinforced lining. Adjacent concrete pours feature
construction joints and continuous reinforcement in joints is not desired to allow
relative movement. Use of water impermeable cast in place concrete lining as an
alternative to membranes is generally not considered due to high demands on
construction quality and elaborate measures required to prevent cracking,
provision of construction joint etc.

1.2.1 Advantages of a cast-in-place concrete lining:

 Suitable for use with any excavation and initial ground support method.
 Corrects irregularities in the excavation.
 Can be constructed to any shape.
 Provides a regular sound foundation for tunnel finishes.
 Provides a durable low, maintenance structure.

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1.2.2 Disadvantages of a cast-in-place concrete lining:

 Concrete placement, especially around reinforcement may be difficult. The

nature of the construction of the lining restricts the ability to vibrate the
concrete. This can result in incomplete consolidation of the concrete around
the reinforcing steel.
 Reinforcement when used is subject to corrosion and resulting deterioration of
the concrete unless stainless steel reinforcement or treated reinforcement is
used. This is a problem common to all concrete structures, however
underground structures can also be subjected to corrosive chemicals in the
groundwater that could potentially accelerate the deterioration of reinforcing
steel.
 Cracking that allows water infiltration can reduce the life of the lining.
 Chemical attack in certain soils can reduce lining life.
 Construction requires a second operation after excavation to complete the
lining.

1.2.3 Design Considerations:

In order to maximize flexibility and ductility, a cast-in-place concrete lining should

be as thin as possible. There are, however, practical limits on how thin a section
can be placed and still obtain proper consolidation. 25cm is considered the
practical minimum thickness for a cast-in-place concrete lining.

Reinforcing steel in a thin section can also be problematic. The reinforcement

inhibits the flow of the concrete making it more difficult to consolidate. If two layers
of reinforcement are used, then staggering the bars may be required to obtain the
required concrete cover over the bars. This can make the forms congested and
concrete placement more difficult. Self consolidating concrete has been in
development in recent years and has been used in unreinforced concrete linings
in Europe with some success. Self consolidating concrete may prove useful in
reinforced concrete linings, however, it is recommended that an extensive testing
program be made part of the construction requirements to ensure that proper
results are, actually obtained.

Cast-in-place concrete is used as the final lining. In many cases a waterproofing

system is placed over the initial ground support prior to placing the final concrete
lining. Placing reinforcing steel over the waterproofing system increases the
potential for damaging the water proofing. In all cases when it is practical, cast-in-
place concrete linings should be designed and constructed as plain concrete, that
is with no reinforcing steel. The presence of the waterproofing systems precludes
load sharing between the final lining and the initial ground support. A basic design
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 assumption is that the final lining carries long term earth loads with no contribution
from the initial ground support.

Ground water chemistry should be investigated to ensure that chemical attack of

the concrete will not occur if the lining is exposed to ground water. If this is an
issue on a project, mitigation measures should be put in place to mitigate the
effects of chemical attack. The waterproofing membrane can provide some
protection against this problem. Admixtures, sulphate resistant cement and high
density concrete may all be potential solutions. This problem should be addressed
on a case to case basis and the appropriate solution be implemented based on
best industry practice.

Concrete behavior in a fire event must also be considered. When heated to a high
enough temperature, concrete will spall explosively. This produces a hazardous
condition for trains and for emergency response personnel responding to the
incident. This spalling is caused by the vaporization of water trapped in the
concrete pores being unable to escape. Spalling is also caused by fracture of
aggregate and loss of strength of the concrete matrix at the surface of the
concrete after prolonged exposure to high temperatures. Reinforcing steel that is
heated will lose strength. Spalling and loss of reinforcing strength can cause
changes in the shape of the lining, redistribution of stresses in the lining and
possibly structural failure. The lining should be protected against fire.

1.2.4 Materials:

Mixes for cast-in-place concrete should be specified to have a high enough slump
to make placement practical. Air entrainment should be used. The moist
environment in many tunnels combined with exposure to cold weather makes air
entrainment important to durable concrete.

Compressive strength should be kept to a minimum. High strength concretes

require complex mixes with multiple admixtures and special placing and curing
procedures. Since concrete lining acts primarily in compression, 28 day
compressive strengths in the range 25 to 30 MPa are generally adequate.

1.3 Precast Segmental Lining:

1.3.1 Description:

Precast segmental linings are used in circular tunnels excavated using a Tunnel
Boring Machine (TBM). It can be used in both soft and hard ground. Several
curved precast elements or segments are assembled inside the tail of the TBM to

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 form a complete circle. The number of segments used to form the ring is a
function of the ring diameter and to a certain respect, construction agency’s
preferences. The segments are relatively thin, 20 to 30 cm and typically 1 to 1.5 m
wide measured along the length of the tunnel.

Precast segmental linings can be used as initial ground support followed by a

cast-in-place concrete lining (the “two-pass” system) or can serve as both the
initial ground support and final lining (the “one-pass” system) straight out of the tail
of the TBM. Segments used as initial linings are generally lightly reinforced,
erected without bolting them together and have no waterproofing. The segments
are erected inside the tail of the TBM. The TBM pushes against the segments to
advance the tunnel excavation. Once the shield of the TBM is passed the
completed ring, is jacked apart (expanded) at the crown or near the spring lines.
Jacking the segments helps fill the annular space that was occupied by the shield
of the TBM. After jacking, contact grouting may be done for filling the annular
space and to ensure complete contact between the segments and the
surrounding ground. A waterproofing membrane is installed over the initial lining
and the final concrete lining is cast in place against the waterproofing membrane.
Horizontal and vertical curvature in the tunnel alignment is created by using
tapered rings. The curvature is approximated by a series of short chords.

Precast segmental linings used as both initial support and final lining are built to
high tolerances and quality. They are typically heavily reinforced, fitted with
gaskets on all faces for waterproofing and bolted together to compress the
gaskets after the ring is completed but prior to advancing the TBM. As the
completed ring leaves the tail of the shield of the TBM, contact grouting is
performed to fill the annular space that was occupied by the shield. This provides
continuous contact between the ring and the surrounding ground and prevents the
ring from dropping into the annular space. Bolting is often performed only in the
circumferential direction. The shove of the TBM is usually sufficient to compress
the gaskets in the longitudinal direction. Friction between the ground and the
segments hold the segment in place and maintain compression on the gasket.
Segmental linings were initially fabricated in a honeycomb shape that allowed for
bolting in both the longitudinal and circumferential directions. Recent lining
designs have eliminated the longitudinal bolting and the complex forming and
reinforcing patterns that were required to accommodate the longitudinal bolts.
Segments now have a flat inside surface. Once adequate strength is achieved,
the segments are inverted to the position they must be in for erection inside the
tunnel. As with segments used for initial lining, horizontal and vertical tunnel
alignment is achieved through the use of tapered segments.

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1.3.2 Advantages of a precast segmental lining:

 Provides complete stable ground support that is ready for follow-on-work.

 Materials are easily transported and handled inside the tunnel.
 No additional work such as forming and curing is required prior to use.
 Provides a regular sound foundation for tunnel finishes.
 Provides a durable low maintenance structure.

1.3.3 Disadvantages of a precast segmental lining:

 Segments must be fabricated to very tight tolerances.

 Reinforcing steel must be fabricated and placed to very tight tolerances.
 Storage space for segments is required at the job site.
 Segments can be damaged if mishandled.
 Spalls, cracked and damaged edges can result from mishandling and over
jacking.
 Gasketed segments must be installed to high tolerances to assure that
gaskets perform as designed.
 Reinforcement when used is subject t corrosion and resulting deterioration of
the concrete.
 Cracking that allows water infiltration can reduce the life of the lining.
 Chemical attack in certain soil can reduce lining life.

1.3.4 Design Considerations:

1.3.4.1 Initial Lining Segments:

Segments used as an initial support lining are frequently designed as structural

plain concrete. Reinforcing steel is placed in the segments to assist in resisting
the handling and storage stresses imposed on the segments. Reinforcement is
often welded wire fabric or small reinforcing steel bars. The segments are
usually cast in a yard set up specially for manufacturing the segments.

When using a structural analysis program for analysis, the structural model
should include hinges (points where no bending moment can develop) at the
locations of the joints in the ring. Using hinges at the joint locations provides the
ring with the flexibility required to adjust to the loads, resulting in the
predominant loading being axial load or thrust. This is an approximation of the
behavior of the lining since joints will transfer some moment. The actual

81
 behavior of a segmental lining can be bounded by two models that have zero
fixity at the joints and full fixity at the joints.

Radial joints in between segments can be flat or concave/convex.

Convex/concave joints facilitate rotation at the joint, allowing the segment to
deform and dissipate moments. Flat joints are more efficient in transferring axial
load between segments and may result in less end reinforcement. In either
case, the ends of the segments that form the joints should be reinforced to
facilitate the transfer of load from one segment to another without cracking and
spalling. The amount of reinforcement used should consider the type of joint and
the resulting load transfer mechanism. Handling and erecting the segments are
also sources of damage at the joints. Reinforcing can mitigate this damage.

The primary load carried by the precast segments is axial load induced by
ground forces acting on the circumference of the ring. However, loads imposed
during construction must also be accounted for in the design. Loads from the
jacking forces of the TBM are significant and can cause segments to damage
and require replacement. These forces are unique to each tunnel and are
function of the ground type and the operational characteristics of the TBM.
Reinforcement along the jacking edges of the segments is usually required to
resist this force. The segments should be checked for bearing, compression and
buckling from TBM thrust loads.

Handling, storage, lifting and erecting the segments also impose loads. The
segments should be designed and reinforced to resist these loads also. When
designing reinforcement for these loads, appropriate codal provisions should be
used (refer clause No. 1.7 of this chapter). Grouting pressure can also impose
loads on the lining. Grouting pressures should be limited to reduce the
possibility of damage to the ring by these loads. The anticipated grouting
pressure should be added to the load effects of the ground loads applied to the
lining.

Initial lining segments are considered to be temporary support, therefore, long

term durability is not considered in the design of the linings.

1.3.4.2 Final Lining Segments:

Segments used as a final lining are designed as reinforced concrete. The

reinforcement assists in resisting the loads and limits cracking in the segment.
Limiting cracking helps make the segments waterproof. Appropriate codal
provisions should be used to design the segments. The segments are
manufactured in a yard set up specifically for manufacturing the segments.

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 Since the segments are cast and cured in a controlled environment, higher
tolerances can be attained than in cast-in-place concrete construction.

Final lining segments can be fabricated with straight or skewed joints. The
orientation of the joint should be considered in the design of the lining to account
for the mechanism of load transfer across the joint between segments. Skewed
joints will induce strong axis bending in the ring and this should be accounted for
in the design of the ring. Whether using straight or skewed joints, segments are
rotated from ring to ring so that the joints do not line up along the longitudinal
axis of the tunnel.

Joint design should consider the configuration of the gaskets. The gasket can
eliminate much of the bearing area for load transfer between joints. Joints
should be adequately reinforced to transfer load across the joints without
damage.

The primary load carried by the precast segments is axial load induced by
ground, hydrostatic and other forces acting on the circumference of the ring. The
presence of the waterproofing systems precludes load sharing between the final
lining and the initial ground support. A basic design assumption is that the final
lining carries long term earth loads with no contribution form the initial ground
support. Loads imposed during construction must also be accounted for in the
design. Loads from the jacking forces of the TBM are significant and can cause
segments to be damaged and require replacement. These forces are unique to
each tunnel and are a function of the ground type and the operational
characteristics of the TBM. Reinforcement along the jacking edges of the
segments may be required to resist this force. The segments should be checked
for bearing, compression and buckling from TBM thrust loads.

Lifting and erecting the segments also impose loads. The segments should be
designed and reinforced to resist these loads. When designing reinforcement for
these loads, the provisions of relevant codes should be used.

Grouting pressure can also impose loads on the lining. Grouting pressures
should be limited to reduce the possibility of damage to the ring by these loads.
The anticipated grouting pressure should be added to the load effects of the
earliest ground loads applied to the lining.

Ground water chemistry should be investigated to ensure that chemical attack

on the concrete lining will not occur when exposed to ground water. If this is an
issue in a project, mitigation measures should be put in place to reduce the
effects of chemical attack. The waterproofing membrane can provide some

83
 protection against this problem. Admixtures, sulfate resistant cement and high
density concrete may all be potential solutions. This problem should be
addressed on a case by case basis and the appropriate solution implemented
based on best industry practice.

Concrete behavior in a fire event must also be considered. When heated to a

high enough temperature, concrete will spall explosively. This produces a
hazardous condition for trains and to emergency response personnel
responding to the incident. This spalling is caused by the vaporization of water
trapped in the concrete pores being unable to escape. Spalling is also caused
by fracture of aggregate and loss of strength of the concrete matrix at the
surface of the concrete after prolonged exposure to high temperatures.
Reinforcing steel that is heated will lose strength. Spalling and loss of reinforcing
strength can cause changes in the shape of the lining, redistribution of stresses
in the lining and possibly structural failure.

1.3.5 Materials:

Concrete mixes for precast segments for initial linings do not require special
designs and can generally conform to the structural concrete mixes provided in
most standard construction specifications. Strengths in the range of 25 to 35
MPa are generally adequate. These strengths are easily attainable in precast
shops and casting yards. Curing is performed by in enclosures and is well
controlled. Air entrainment is desirable since segments may be stored outdoors
for extended periods of time and final lining segments may be exposed to
freezing temperatures inside the tunnel.

Steel fiber reinforced concrete has become a topic of discussion and research
for precast tunnel linings. Theoretically, steel fibers can be used in lieu of steel
reinforcing bars. The fibers can potentially eliminate the need for fabricating the
steel bars to very tight tolerances, provide ductility for the concrete and make
the segments tougher and less damage prone during construction.
Unfortunately, there is no design code for the design of steel fiber reinforced
concrete. The recommended practice, until further research is conducted and
design codes are developed, is to use steel fibers in segments where the design
is conducted and the lining is found to be adequate without reinforcing. The
steel fibers then can be included in the concrete to improve handling
characteristics during construction. A testing program is required by the
specifications to have the contractor prove via field testing that the fiber
reinforced segments can withstand the handling loads imposed during
construction. The fibers then can be used lieu of reinforcement that would be
installed to resist the handling loads.

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 Concrete mixes for one pass lining segments have strengths ranging from 35 to
48 MPa. Higher strengths are easily obtainable in precast shops and assist in
resisting handling and erection loads.

1.4 Lattice Girders and Rolled Steel Sets

Lattice girders are lightweight, three-dimensional steel frames typically

fabricated of three primary bars connected by stiffening elements. Lattice girders
are used in conjunction with shotcrete and once installed locally act as shotcrete
lining reinforcement. Lattice girders are installed to provide:

 Immediate support to the ground (in a limited manner due to the low girder
capacity)
 Control of tunnel geometry (template function)
 Support of welded wire fabric (as applicable)
 Support for fore poling pre-support measures.

The girder design is defined by specifying the girder section and size and
moment properties of the primary bars. To address stiffness of the overall girder
arrangement the stiffening elements must provide a minimum of five percent of
the total moments of inertia. The arrangement of primary bars and stiffening
elements is such as to facilitate shotcrete penetration into and behind the girder,
thereby minimizing shadows.

In particular cases where, for example, immediate support is necessary for

placing heavy spilling for pre-support, the use of rolled steel sets may be
appropriate. In such instances steel sets are used for implementation of
contingency measures.

1.5 Ribs and Lagging

Ribs and lagging are not used as much now as they were a couple of decades
ago. However, there are still applications where their use is appropriate, such as
unusual shapes, intersections, short starter tunnels for TBM, and reaches of
tunnel where squeezing or swelling ground may occur.

1.5.1 Design Issues:

The design approach typically assumes the ribs are acted upon by axial thrust
and by bending moments, the latter a function of the spacing of the lagging or
blocking behind the ribs. In today’s applications, steel ribs are often installed

85
 with shotcrete being used instead of wood for the blocking (lagging) material.
When shotcrete is used, it often does not fill absolutely the entire void between
steel and rock. Hence, with properly applied shotcrete appropriate maximum
blocking point spacing be taken in the design.

1.6 Principles of Ground Structure Interaction:-

1.6.1 Structural Design Issues (General):-

(i) The processes of ground pretreatment, excavation and ground stabilization

after the pre existing state of stress in ground before lining comes in contact
with ground.

(ii) A tunnel lining is not an independent structure acted upon by well defined
loads, and its deformation is not governed by its own internal elastic
resistance. The loads acting are ill defined and its behavior is governed by
properties of surrounding ground.

(iii) Design of tunnel lining is basically not a structural problem but a ground-
structure interaction problem with ground playing predominant role.

(iv) Tunnel lining behavior is a four dimensional problem. During construction,

ground conditions at tunnel head involve transverse as well as longitudinal
arching, cantilevering from unexcavated face. Most importantly all ground
properties are time-dependent especially in short term, leading to commonly
observed phenomenon of stand-up time. Thus timing of lining installation is
an important variable.

(v) The most serious structural problems encountered with actual lining behavior
are related to absence of supports due to inadvertent voids left behind lining
rather than on intensity and distribution of load.

(vi) In most of the cases the bending strength and stiffness of structural lining are
small compared with those of the surrounding ground. The change in lining
properties does not significantly affect deformation of lining, which primarily
depends on ground properties. Therefore, lining behavior should be judged
by adequate ductility to conform to imposed deformation rather than strength
to resist bending stresses.

(vii) Structural analysis of tunnel lining has been a subject of numerous papers
and theories. Great disparity of opinion exist on accuracy and usefulness of
these analyses eg. Beam-spring models, three dimensional models, (more

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 sophisticated analysis), empirical methods (for soft ground) (2D general
purpose structural analysis program) and numerical methods (modeling
lining and surrounding ground as a continuum using 3D FEM).

1.6.2 Structural Design Issues: NATM

1.6.2.1 Ground-Structure Interaction:

The NATM realizes excavation and support in distinct stages with limitations on
size of excavation and length of round followed by the application of initial
support measures. In particular the shotcrete lining has an interlocking function
and provides an early, smooth support. To adequately address this sequenced
excavation and support approach the structural design shall be based on the
use of numerical, i.e. finite element, finite difference, or discrete element
methods. These numerical methods are capable of accounting for ground
structure interaction. They allow for representation of the ground, the structural
elements used for initial and final ground support, and enable an approximation
of the construction sequence.

1.6.2.2 Numerical Modeling:

 Two (2)-Dimensional and Three (3)-Dimensional Calculations:

In general, use of two-dimensional models is sufficient for line structures.
Where three-dimensional stress regimes are expected, such as at
intersections between main tunnel and cross passages, or where detailed
investigations at the tunnel face are undertaken, three-dimensional models
should be used.

 Material Models:
In representing the ground, the structural models shall account for the
characteristics of the tunneling medium. Material models used to describe
the behavior of the ground shall apply suitable constitutive laws to account
for the elastic, as well as inelastic ranges of the respective materials.

1.6.2.3 Ground Loads – Representation of the NATM Construction Sequence:

Tunnel excavation causes a disturbance of the initial state of stress in the

ground and creates a three-dimensional stress regime in the form of a bulb
around the advancing tunnel face.

It is important to portray excavation and support sequencing closely in the

numerical analyses. For shotcrete lining structural assessments it is important to

87
 distinguish between a “green” shotcrete when installed and when it has
hardened to its 28-day design strength. Green shotcrete is typically simulated
using a lower modulus of elasticity in the computations. A value of
approximately 1/3 of the elastic modulus of cured shotcrete is commonly used to
approximate green shotcrete in 2-D applications. In 3-D simulations the
shotcrete may be modeled with moduli of elasticity in accordance with the
anticipated strength gain in the respective round where it is installed.

The installation of the final tunnel lining generally occurs once all deformations
of the tunnel opening have ceased. To account for this fact the calculations
perform installation of the final lining into a stress-free state. The final lining
becomes loaded only in the long-term resulting from a (partial) deterioration of
the initial support (shotcrete initial lining and rock bolts in any), rheological long-
term effects and ground water if applicable. Although modeling of the final lining
is often undertaken by embedded frame analyses its analysis within a ground-
structure interaction numerical model will be most appropriate and can follow
directly after the initial support is installed.

In addition to the ground loads, the concrete lining will be loaded with
hydrostatic loads in un-drained or partially drained waterproofing systems. This
load case generally occurs well before the final lining is loaded with any ground
loads and shall be considered separately in the calculations.

Final lining calculations consider the existence of the waterproofing system,

which is embedded between the initial shotcrete lining and the final lining. A
plastic membrane will act as a de-bonding layer in terms of the transfer of shear
stresses. Therefore simulation techniques should be used to simulate this “slip”
layer. This is accomplished by only allowing the transfer of radial forces from the
initial lining onto the final lining.

1.6.2.4 Lining Forces:

Section forces and stresses for beam (2-D) or shell (3-D) elements are
ascertained from modeling. Section force and moment combinations are used to
evaluate the capacity of the initial shotcrete and final concrete linings using
accepted concrete design codes. (Refer Clause No. 1.7 of this chapter).

Based on this evaluation the adequacy of lining thickness and its reinforcement
(if any) is assessed. If the selected dimensions are found not to be adequate
then the model must be re-run with increased dimensions and/or reinforcement.
The process is an iterative approach until the design codes are satisfied.

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 These calculations do not distinguish between the type of lining application and
therefore shotcrete and cast-in-place final linings are treated in the same
manner within the program using the material properties and characteristics of
concrete.

1.7 Application of Codes:-

Structural codes should be used cautiously. Most codes have been written for
above ground structures on the basis of assumptions that do not consider
ground-lining interaction. Accordingly, the blind application of structural design
codes is likely to produce limits on the capacity of linings that are not warranted
in light of the substantial contributions from the ground and the important
influence of construction method on both the capacity and cost of linings.
American Road Tunnel Manual specifies use of American Concrete Institute
(ACI), ACI 318 and AASTHO LRFD Bridge Design Specifications with mention
of use of German Industry Standard DIN 1045 for cast-in-place concrete final
lining by some authorities.

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 Chapter 8: Instrumentation & Monitoring

1.0 General

It is recommended that a geo-technical instrumentation and monitoring

program should be planned as an integral part of the tunneling work. For
such a program is to be successful, it is essential that following basic
requirements are met:-

 must be carried out for well-defined purposes

 must be well planned & executed
 must be well supported by competent staff throughout the construction
period (& subsequent period if required) for:-

 analysis & interpretation of data/results from the monitoring

program
 taking decision for the required follow up action/corrective action
based on data/results from the monitoring program

Thus, the essential components of a successful instrumentation & monitoring

program are:-

 Definition of need and objective.

 Planning and design.
 Execution of program.
 Interpretation of data.
 Action based on monitoring results.

All of these components must be carefully planned in advance. If the data

obtained cannot be properly interpreted in a timely fashion, or if no action is
foreseen to be taken based on the data, the instrumentation program will
have no purpose and should not be implemented

1.1 Purpose of instrumentation and monitoring program

Geotechnical instrumentation & monitoring programs are carried out for one
or more of the following purposes:

1. Characterization & determination of initial site conditions

2. Design & Design Verification :-

 NATM monitoring of displacements and loads is an essential part of the

construction process, providing input to the ongoing process of design
and verification during construction.
 Where initial ground support is selected based on conditions
encountered, monitoring can verify the adequacy of the support and
indicate if more support is required.

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  May be used to obtain data from pilot tunnels, or shafts which can be
used for design of tunnel.
 Decisions regarding design of final lining may be taken.

3. Construction Control:

 Early monitoring during construction can help in planning of later

construction procedures or help decide whether contingency plans
need to be used.
 Monitoring can be used to diagnose flaws in the contractor’s
construction methodology and indicate the required improvements.

4. Safety: In the process of determining the adequacy of ground support,

monitoring also serves a safety function, warning of the potential for
ground failure.

5. Regulatory/Environmental requirements: Monitoring may be

required to ensure compliance with regulatory/environmental
requirements (e.g., groundwater lowering, ground settlements,
vibrations)

6. Performance Monitoring: Instruments are used to monitor the in-

service performance of a structure. For example, monitoring loads on rock
bolts and movements within a tunnel can provide an indication of the
stability of tunnel.

7. Contractual Documentation: Monitoring data can also be used for

avoiding/settling disputes between the Railways and the contractor/s.

1.2 Items to consider in planning a successful Instrumentation and

Monitoring Program -

1. Define the project conditions: The official/s planning and designing

should be/ should become familiar with project conditions including
type and layout of the tunnel or shaft, subsurface stratigraphy and
engineering properties of subsurface materials, groundwater
conditions, status of nearby structures or other facilities,
environmental conditions, and planned construction method.

2. Predict mechanisms that control behavior: Before defining a

program of instrumentation and monitoring, one or more working
hypotheses must be established for mechanisms that are likely to
control behavior. Instrumentation should then be planned around
these hypotheses. For example, if the purpose is to monitor safety,
hypotheses must be established for mechanisms that could lead to
rock or support failure.

3. Define the purpose of the instrumentation and monitoring and

the questions that need to be answered: Every instrument should

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 be selected and placed to assist in answering a specific question. If
there is no question, there should be no instrumentation.

4. Select the parameters to be monitored: The parameters that are

typically monitored are:
 Convergence
 Crown settlement
 Floor heave
 Load in rockbolts/anchors
 Stress in shotcrete/ concrete
 Groundwater pressure
 Water pressure acting on lining
 Surface settlement
 Vertical and horizontal deformation of buildings and other
structures
 Vertical and horizontal deformation of the ground at depth

It is important to consider which parameters are most significant for

each particular situation. For example, if the question is “Is the
support overloaded?”, stress or load in the support is likely to be the
primary parameter of interest. However, recognizing that stress is
caused by deformation of the rock, it may also be necessary to
monitor deformation. By monitoring both cause and effect, a
relationship between the two can often be developed, and action can
be taken to remedy any undesirable effect by removing the cause.

5. Predict magnitudes of change and set response values for

action to be taken: An estimate of the maximum possible value or
the maximum value of interest will determine the instrument range,
and the minimum value of interest determines the instrument
sensitivity or accuracy. Accuracy and reliability are often in conflict
since highly accurate instruments may be delicate and/or fragile. A
predetermination should be made of instrumentation readings that
indicate the need for remedial action. The concept of green, yellow,
and red response values is useful. Green indicates that all is well;
yellow indicates the need for cautionary measures including an
increase in monitoring frequency; and red indicates the need for timely
remedial action.

6. Devise remedial actions and arrange for implementation

7. Assign duties and responsibilities for all phases: Duties during

the monitoring program include planning, instrument procurement,
calibration, installation, maintenance, reading, data processing, data
presentation, data interpretation, reporting, and deciding on
implementation of the results. When duties are assigned for
monitoring, the party with the greatest interest in the data should be
given direct responsibility for producing it accurately.

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1.3 Instrument selection and locations:

(1) Reliability is the most desirable feature when selecting monitoring

instruments. Lowest first cost of an instrument should not dominate the
selection of an instrument. A comparison of the overall cost of
procurement, calibration, installation, maintenance, reading, and data
processing of the available instruments should be made. The least
expensive instrument may not result in least overall cost because it may
be less reliable since cost of the instruments themselves is usually a
minor part of the overall cost.

(2) Users need to develop an adequate level of understanding of the

instruments that they select and often benefit from discussing the
application with the manufacturers staff before selecting instruments.
During the discussions, any limitations of the proposed instruments
should be determined.

(3) Choosing locations for the instruments should be based on predicted

behavior of the tunnel or shaft. The locations should be compatible with
the questions and the method of analysis that personnel will use when
interpreting the data. A practical approach to selecting instrument
locations involves following three steps:

 First, identify areas of particular concern, such as structurally weak

zones or areas that are most heavily loaded, and locate appropriate
instrumentation.

 Second, select zones where predicted behavior is considered

representative of behavior as a whole. These zones are regarded as
primary instrumented sections.

 Third, because the primary zones may not be truly representative,

install simple instrumentation at a number of secondary
instrumented sections to serve as indices of comparative behavior.
If the behavior at one or more of the secondary sections appears to
be significantly different from the primary sections, additional
instruments can be installed at the secondary section as
construction progresses.

1.4 Plan recording of factors that affect measurements:

(1) For proper interpretation of virtually all site instrumentation data, it is

essential to monitor and record site activities and climatic conditions
that can have an effect on the measurements obtained. These include
at least the following:

 Progress of excavation (e.g., distance of advancing tunnel face

from installation).

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  Excavation of adjacent openings, including effects of blasting.
 Installation of lining or other ground support.
 Installation of drains or grouting.
 Unusual events (ground instability, excess water inflows, etc.).
 Continued monitoring of groundwater inflow into the tunnel.

(2) Usually, variations in the geology or rock quality have a great effect on
monitoring data. While it is generally recommended to map the
geology along an important underground facility during construction, it
is especially important in the vicinity of extensive monitoring
installations.

(3) Establish procedures to ensure data correctness: In critical

situations, more than one of the same type of instrument may be used
to provide a backup system even when its accuracy is significantly less
than that of the primary system. Repeatability can also give a clue to
data correctness. It is often worthwhile to take many readings over a
short time span to determine whether a lack of normal repeatability
indicates suspect data.

(4) Plan redundancy, regular calibration and maintenance

(5) Plan data collection and data management: The plan of data
collection includes details about frequency of readings, data
transmission and data storage. Readings may be taken at intervals,
continuously (real time), depending on specific construction stages or
time events. Written procedures for collecting, processing, presenting,
interpreting, reporting, and implementing data should be prepared
before instrumentation work commences in the field

1.5 Typical Instruments for monitoring tunneling work:

The most important parameters to be monitored can be subdivided in

following groups:

 Deformations (displacements, strains, changes in inclination etc.)

 Stresses
 Forces on structural elements (bolt force, normal load on a
compression element or steel arch)
 Piezometric levels

1.6 Following instruments are typically used to measure the above parameters:

1. Bore hole extensometer to measure deformations of rock mass and

adjacent or surrounding soil.
2. Load cell to measure load in rock bolts
3. Load cell to measure load in ribs and struts
4. Strain gauge to measure strain in ribs and struts
5. Strain gauge to measure strain in shotcrete

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 6. Shotcrete stress cell to measure stress in shotcrete
7. Piezometer to measure pore water pressure around tunnel
8. Convergence measurement by mechanical methods-tape extensometer
9. Convergence measurement by optical methods- Prism Targets
10. Inclinometer and magnetic settlement devices: to monitor lateral
movements (x and y directional movements) and settlements (z
directional movements) around a tunnel excavation or on a slope.
11. Measuring Anchor or rock bolt extensometer to measure distribution of
load exerted on grouted rock bolts
12. Geophone: to determine seismic response

A typical arrangement of installation of instruments for a tunneling project is

shown below:-

2.0 Organizational Issues

In contract documents, responsibilities for installation and commissioning,

calibration, monitoring, information flow, data interpretation and reporting
etc. must be clearly defined.

It may be advantageous to appoint an independent monitoring contractor

who carries out the monitoring work and, on a real-time basis, delivers the
results to all parties involved in the execution of the tunnel project (Railways,
designer, contractor, Proof Consultant etc). The evaluation of the monitoring
results should also be carried out on a real-time basis by a suitably
experienced third party (either the Railways with their Proof Consultant or
the design engineer responsible for the detailed design of the tunnel). The
contract conditions should provide the necessary empowerment to persons to
implement immediate works as per the results of the monitoring.

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 Chapter 9: Drainage

The planning and design of a tunnel drainage system should begin from
geotechnical exploration phase itself with an assessment of the potential sources
and volumes of water expected during and after construction.

The drainage arrangements for the keeping off and removing of water may be
classified broadly in following categories:-

i. Pre-drainage or preventing the entry of excess water from entering

the tunnel before starting the tunnel construction work. This includes
arrangements like ground water pumping, curtain grouting, specialty
chemical grouting etc.

ii. Dewatering of the tunnel i.e. removing the water that has entered
the tunnel during the construction of tunnel. During construction,
water may come in the tunnel from the following sources:-

 Wash water , which is used for washing drill holes and water from
other construction related activities
 Ground or sub-soil water

Dewatering pumps (located at sumps created for the purpose) are

normally used for dewatering of tunnels during construction if the
natural drainage cannot be achieved. Water from open approach
areas should not be allowed to enter the tunnel either by providing
side drains taking water away from tunnel face or by use of
dewatering pumps.

iii. Permanent drainage i.e. removing the water from the tunnel after
its completion. After construction, water may come in the tunnel from
the following sources:-

 Tunnel seepage (through tunnel lining)

 Weep Holes
 From open approach areas
 From openings to surface

Drainage can be accomplished either by a gravity flow system or a pumped system;

the former being the preferred option. Suitable drainage system needs to be
designed for and provided in the tunnel for the estimated quantity of flow. Weep
holes may be constructed through the tunnel lining to tap the ground water.
Geosynthetic based drainage system may also be used for drainage as well as
sealing purposes. Lining of a sealed tunnel has to be designed appropriately.

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 Chapter 10:Ventilation, lighting & Fire safety

1.1 Tunnel Ventilation

Ventilation is required in railway tunnels primarily to:

1. To remove the heat generated by locomotive units

2. To flush the tunnel of air contaminants

Ventilation can be either in form of natural ventilation or mechanical/forced

ventilation.

Ventilation systems (both temporary & permanent) shall be designed to

supply sufficient fresh air to all parts of the tunnel; maintain exhaust
pollutants within prescribed limits; to provide adequate visibility from the
accumulation of smoke & to provide a hazard free environment for tunnel
users.

Many factors have an influence on the choice of ventilation system and

should be taken due account of in accordance with their relative importance
to a particular scheme. The end result for a ventilation system shall be an
aerodynamically sound system, one that provides satisfactory environmental
conditions inside the tunnel and adjacent to it, controls smoke in the event of
fire & has acceptable capital and running costs while providing ease of
operation & maintenance.

The parameters of a suitable and economical ventilation system for a

particular tunnel layout will be determined by:

 The purpose, length, gradient, cross-section, topography and general

configuration of the tunnel.
 Its location and general impact on the local environment,
Environmental considerations at portals and shaft outlets (if provided)
 Traffic volume & direction, number of tracks, speed & traffic
Composition
 Type of traction
 Fires and their likely severity
 Capital investment and running costs, maintainability.

1.2 Tunnel lighting

Tunnel lighting is required for the following purposes:

 To provide sufficient illuminance to enable passengers and staff to

detrain and to make their way safely out of the tunnel

 To assist train crews in their orientation and improve their visibility of

the track. Adequate tunnel lighting allows drivers to quickly adjust to

97
 the light within, identify possible obstacles, and negotiate their
passage without reducing speed.
 To let the inspectors or workers at track level could clearly see the
track elements/condition or go through their routine inspections
without using flashlights.

1.2.1 Design of tunnel lighting systems: The design of the lighting system should
also:

a) Take full account of the possible conditions of the tunnel following an

emergency (for example, fire and smoke)
b) Consider when and how the lighting should function. Options include:
i) Permanently switched on
ii) Switched on automatically following an incident or condition
ii) Manually controlled
c) Consider how the maintained illuminance will be provided in the event of
failure of the normal power supply.

1.3 Fire Safety in Tunnels

Safety in the event of a fire is of paramount importance in a tunnel. For

planning purposes, it is important to understand the fire safety issues/risks
relevant for a tunnel and to make appropriate plans for the same based on
risk perception. Some of the key aspects to be considered are:-

 Fire risk mitigation plan: Sources of flammable materials and potential

sources of ignition should be identified. A plan to minimize risk should
be drawn up
 Choice of Structural Elements
 Fire-detection and surveillance systems, including heat and smoke
monitoring Systems
 Communication System
 Traffic Control Systems
 Fire Protection (i.e., fire hydrants, water supply, portable fire
extinguisher, etc.)
 Emergency Egress: Emergency walkways, refuges & exits and
Emergency lighting
 Emergency response plan.

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 Chapter 11: Tunnel Survey

1.0 Tunnel Survey

Surveying plays a major role in the overall engineering and construction of

tunnels right from the planning stage to the final completion. Good
competence in Surveying is necessary for:-

 Proper initial planning

 Integration of geo-technical and geographical data with topographical
mapping (and utility mapping if located in urban area)
 Actual alignment and guidance of tunnel, adit and shaft construction

It is therefore necessary that survey engineers should be involved right from

the inception of planning stage to design and final construction stage. The
results of these surveys would provide more cost-effective existing-
conditions data, ranging from topographic mapping to detailed utility
surveys; the use of appropriate coordinate systems tailored to meet the
specific needs of the project; optimized alignments; more accurate surface
and subsurface horizontal and vertical control net-works properly tied to
other systems and structures; precise layout and alignment of tunnel, adit &
shaft.

1.1 Stipulations recommended to be included in contract documents:

Except in rare instances, the contractor should be entrusted with

responsibilities for all surveying conducted for the construction work,
including control of line and grade and layout of all facilities and structures.
Railway officials must conduct verification surveys at regular intervals and
also ensure that the work is properly tied to adjacent existing or new
construction.

It is therefore very important that provisions of contract documents are

properly framed to clearly stipulate the responsibilities of Railways &
Contractor. Also, the contract documents must contain all reference material
necessary to conduct surveying control during construction. This includes
the following:

1. Mathematized line and grade drawings, overlain on profiles and

topography from the mapping efforts. Designers will use a working line as
a reference, usually the invert of the tunnel or some other defined line.
2. All parts of the cross section along the tunnel are referenced to the
working line.
3. Drawings showing alignment posts and benchmarks to be used as primary
controls. These should be verified or established for the project.
4. Drawings showing existing conditions as appropriate, including all affected
utilities, buildings, or other facilities.
5. Interfaces with other parts of the project, as required.

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 6. Specifications stating the accuracy requirements and the required quality
control and quality assurance requirements, including required
qualifications for surveyors. Minimum requirements to the types and
general stability of construction benchmarks and alignment posts may
also be stated.
7. Benchmarks and alignment posts are sometimes located where they may
be affected by the work or on swelling or soft ground where their stability
is in doubt. Such benchmarks and alignment posts should be secured to
safe depth.
8. Where existing structures and facilities may be affected by settlements or
groundwater lowering during construction, preconstruction surveys should
be conducted to establish a baseline for future effects. Such surveys
should preferably be supplemented by photographs.

1.2 Surveying Steps in alignment control of Tunnels:

Setting out of centre line of tunnel at exact location and elevation is to be

done in various steps as mentioned below:

(i) Establishment of temporary benchmarks and alignment posts: The

contractor’s surveyor will establish temporary benchmarks and
alignment posts as required for the work and will ensure their
stability. In case stability of temporary benchmarks and alignment
posts is in danger or they have been disturbed, contractor shall take
prompt measures to transfer & re-establish these temporary
benchmarks and alignment posts. Proper documentation for the same
should be maintained.
(ii) Surface Survey (setting out tunnel on ground surface)
(iii) Transferring the alignment underground (transfer of centre line from
surface to underground)
(iv) Underground setting out: care should be taken to eliminate
cumulative error
(v) Transferring levels underground (underground leveling): care should
be taken to eliminate cumulative error

Railway officials should be properly trained in operation of surveying

equipments (particularly the Total Station; which is presently the most
commonly used surveying equipment for alignment control of tunnels)
GPS is not suitable for locations where GPS antenna cannot be
exposed to the satellite via direct line of sight. As such, GPS is not
used for survey in interior of tunnels.

Theodoloites, Total Stations & EDMs cannot be adjusted or calibrated

in the field. This work must be done in a competent service facility as
recommended by the OEM. Level instruments, however, require
regular testing to assure that the horizontal crosshair defines a true
level plane.

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 Chapter 12: Problems in Tunnelling

1.0 Common problems encountered during tunneling are:-

• Daylighting,
• Underground collapse,
• Rock burst,
• Inrush of water and
• Portal collapse

These are briefly described below:-

 Daylighting: In this case the ground is unravelled to the surface,

mainly due to erosion by underground water. Propagation of the failure
to the surface can be extremely quick. This is often termed as
Chimney/cavity formation. Daylighting is normally caused due to
reason/s like weakness in the crown of a tunnel, insufficient cover to
overlaying permeable water bearing strata , insufficient cover to
surface or insufficient cover to overlaying deposit materials.

Fig: Daylighting due to weakness in the crown of a tunnel

Fig: Daylighting due to Insufficient cover to overlaying permeable

water bearing strata

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 Fig: Daylighting due to Insufficient cover to surface

Fig: Daylighting due to insufficient cover to overlaying deposit

materials

Underground collapses: This type of collapse does not reach the surface.
These can be subdivided into:-

 Roof collapse: breaking down and caving in of competent or loose rock

at the tunnel roof.
 Stope: local progressive upward roof collapse in thick but fractured
rock strata.
 Side-wall caving: Breaking and caving in of the side walls of a tunnel -
takes place often in conjunction with roof caving.
 Heading hurrying on ahead of the driving: affects the area of several
meters in advance of the heading & involves caving of the roof as well
as caving of the side walls- occurs mainly during tunneling by
mechanized means or as a result of standstill or disruptions in work.

Rock burst: Rock burst is a term used to describe rock failures ranging in
magnitude from the explosion of small fragments of rock from underground
excavation faces or side walls to sudden collapse of a large section of a

102
 tunnel or an excavation. A burst is defined as a sudden and violent explosion
of rock in or around an excavation. Failure is normally associated with high
stress and brittle or brittle-elastic materials.

The occurrence of rock bursts in deep mining tunnels is well known and
requires special precautions during construction and adoption of appropriate
support measures. Basically, the most common form of rock burst
manifestation is the sudden ejection into the excavation of fractured and
detached rocks from the tunnel periphery due to a rapid strain relief process.

Ingress of water / Inrush of water: Water inflow causes various degrees

of difficulty in tunnels. Much depends on preparedness, and on whether or
not discontinuity and fault infillings are washed out in the process. This may
cause exaggerated over break and chimney formation, an unsafe working
environment.

The ingress of water in underground excavations may result from geologic

and manmade conditions. Groundwater inflow influences the construction
procedure, tunnel stability, and the environment.

Portal collapses: The portal areas frequently represent some of the most
problematic points during the excavation of a tunnel. Several factors, for
example the direction of excavation, the morphology of the site, the geo-
mechanical characteristics of the terrain etc. influence the portal problems.

While it is highly desirable that the location selected for the portal be in fresh
rock with cover of the same order as tunnel width and height, environmental
constraints or other relevant considerations will sometimes dictate that the
portal be located where there is low cover, weathered rock, or even soil.
Where rock is exposed, the preconstruction of a reinforced concrete portal
structure will still be of substantial assistance.

2.0 Common causes:

2.1 Geological & Geo-mechanical conditions:

a) Rock alteration: The natural processes of weathering produce rock

alteration which can be of major importance to tunnelling. Weathering
reduces the strength of the rocks and can extend to considerable depths
by the action of groundwater movement. Pockets of highly weathered

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 rocks usually contain water and can be under appreciable hydrostatic
pressure head. Consequently they can possess the ability to rapidly flow
into an excavation if disturbed by underlying or adjacent tunneling
activities.

b) High rock stress: Instability due to excessively high rock stress is also
generally associated with hard rock and can occur when mining at great
depth or when very large excavations are created at reasonably shallow
depth. Tunnelling in steep mountain regions or unusually weak rock
conditions can also give rise to stress-induced instability problems.

c) Faults: Collapses due to adverse structural geology tends to occur in

hard rocks which are faulted and where several sets of discontinuities are
steeply inclined.

d) Joints: Where a rock fracture results in no significant visible

displacement at the plane of fracture, then this is commonly referred to
as a joint. Their frequency and orientation are related to the nature of the
stress field with tensional and compressive states coupled with folding
and faulting playing important roles. Appreciable intensification of jointing
can be expected in close proximity to the axis of severely folded rocks and
adjacent to major faults. Joint patterns as observed at surface rock
exposures may not necessarily exhibit close similarity with those
encountered in the tunnel, with the exception of the portal areas. Joints
observed in surface rocks may have developed primarily due to climatic
and weathering effects, as for example, due to expansion and contraction
cycles, and therefore are most likely to be of limited depth of penetration
below the surface.

Essentially, joint patterns represent structural weaknesses in rock

masses, and can substantially influence the stand-up time of different
rock types. They are likely to influence the mode of rock failure and
character of its collapse potential during tunnel excavation operations.
Stability problems in blocky jointed rock are generally associated with
gravity falls of blocks from the roof and sidewalls. Consequently, the joint
patterns require special considerations when giving attention to the choice
and application of support and particularly for temporary measures. Rock
joint patterns should be taken into account at the tunnel design stage and
when considering selection of the permanent support system.
e) Folded rock masses: The most common form of deformation of rock
masses is that of folding and is especially conspicuous in layered rock
structures, although folding occurs in all rock types. Folds occur on widely
differing scales ranging in wavelengths from the order of centimetres to
kilometres. The intensity of folding reflects the degree of localized
distortion and relative slipping within different parts of the affected rock
mass. Folded strata allow natural traps to form which attract
accumulation in significant quantities of natural gas and water. Severely
distorted folds are frequently accompanied by plastic behaviour of rocks
especially in the softer sediments and in metamorphic rocks.

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 f) Groundwater aspects: The presence of groundwater in very large
quantities is recognized as a major hazard in addition to causing
operational difficulties in respect of tunnel construction works. Potential
problems from groundwater inflow during tunnelling can be predicted to a
large extent in many situations by a comprehensive site investigation
employing deep boreholes. Predicting with accuracy the likely water inflow
quantities is, however, difficult, and detailed monitoring and regular
review of conditions together with the adoption of special measures such
as de-watering or injection programs need consideration.

g) Karst formations: Karst development is the occurrence of solution

features in limestone and related carbonate rocks, and gives rise to
natural caverns and sinkholes through which water can flow.

h) Squeezing ground conditions: Squeezing ground commonly refers to

weak, plastic rock materials which displace into the tunnel excavation
under the action of gravity and from the effect of stress gradients around
the tunnel opening (Barla, 2002).

Plastic and semi-plastic rocks which are sensitive to deformation and

failure at relatively low stress levels are likely to exhibit squeezing
behaviour. Squeezing rock slowly advances into the tunnel without
perceptible volume increase. It has been noted that visible deformation of
the tunnel boundary is most obvious in the portion below springing line.
Heaving of invert is commonly observed especially in non-circular tunnels.

Squeezing occurs when the unconfined compressive strength of the rock

mass is less than the increased tangential stress (due to tunnel
excavation). Rate of squeeze and rock loads are somewhat dependent on
tunnel size and rate of advance. It is essential in squeezing (or swelling)
conditions to establish a program of convergence point installation that
will be used to monitor the amount and rate of movement of the tunnel
walls. This information would be useful in determining the support
requirements as tunneling progresses.

Except in extreme conditions, squeezing is almost always self-limiting and

will not occur vigorously, or at all, once the intruding material has been
removed. It may well be that the re-excavation of a failed tunnel opening
will encounter much less difficult conditions.

An empirical approach can be used for predicting ground conditions (Goel

et al., 1995b). This approach suggests that squeezing ground will be
encountered when:-

H.a0.1> 260 N0.33

where,
H = tunnel depth in metres,
a = tunnel radius in metres,
N = rock mass number (i.e., Barton's Q keeping SRF = 1),
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 = (RQD/Jn)(Jr/Ja)Jw
RQD = rock quality designation,
Jn = joint set number,
Jr = joint roughness number,
Jw = joint water reduction factor

Prediction of the squeezing ground condition alone is not enough. It is also

necessary to ascertain the expected support pressure and the tunnel closure
for effective handling of squeezing ground. Once the optimum desirable
closure is known, flexible supports can be designed to absorb it and
accordingly the excavation size can be increased so that re-excavation is not
required to accommodate the closure.

i) Swelling ground conditions: Swelling behaviour denotes the response of

rock to the presence of water. Swelling phenomena are generally associated
with argillaceous soils or rocks derived from such soils. Rocks which are rich
in clay minerals are likely to have pronounced swelling characteristics.

In the field its quite hard to distinguish between squeezing and swelling
especially since both the conditions are often present at the same time.
Swelling may continue as long as free water and swelling minerals are
present.

The squeezing ground can be distinguished from swelling ground on the basis
that under the former, the movement is visible as soon as the excavation is
made, on other hand, swelling ground is relatively slow process and the time
factor is involved.

Many European railway & highway tunnels constructed in swelling susceptible

formations are still being periodically repaired even a century after their
construction. Since the swelling will not passivate in the same way as
squeezing generally will in rock, tunnel supports must be designed to resist
the swelling pressure.

j) Sloping ground surface conditions: Instability is sometimes caused due

to the nature of the sloping ground surface overlying the tunnel location.
Such sloping ground may be inherently unstable without any disturbance
created by construction of the tunnel. In other situations, however, the
tunnel may introduce changes in the stability conditions of the slope.
Groundwater conditions may also change. The tunnel excavation may prove
to be a significant weakening influence in the proximity of a potential landslip
area.

2.2 Inadequate design and specifications: e.g. Inappropriate support

system, inadequate specification of construction materials and of tolerances
on profiles etc.

2.3. Mistakes at the construction stage: e.g. use of sub-standard materials

and tools, violation of design assumptions, specification requirements, lining

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 not constructed to specified thickness, insufficient shotcrete strength and
thickness, belated placing of the means of support.

2.4 Interruptions & breaks

2.5 Delayed decision making

Tunnels require the deployment of considerable skill and care in their

investigation, planning, design, construction and monitoring if they are to be
safely constructed. Several of the tunnel problems described above often
arise due to failure to properly plan and design for uncertainties, in particular
for an unfavourable change in ground conditions. Procedures can be
developed to overcome these uncertainties and permit safe tunnel
construction, but their successful application requires the proper
management of complex technical issues.

Every collapse requires careful analysis because, on the one hand, the cost
questions have to be settled, and on the other hand, conclusions for the
continuation of work can be drawn from the knowledge gained in this way.
Usually, the problem results from a combination of several unfavourable
factors.

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 References:
i) Tunnel Engineering Hand Book, By: John O. Bickel, Thomas R. Kuesel,
Elwyn H. King, 1997.

ii) Road Tunnel Manual, US Department of Transportation, Federal Highway

Administration, FHWA-NHI-09-010, USA, March 2009.

iii) Road Tunnel Design Guidelines, US Department of Transportation, Federal

Highway Administration. July, 2004.

iv) Introduction to Tunnel Construction by David Champman, Nicole Metje and

Alfred Stark

v) Tunnelling and tunnel mechanics by Dimitrios kolymbal.

vi) ITA general Report on Conventional Tunneling method.

vii) ITA Report on guidelines for Design of the tunnels.

viii) IS 4880-1987 Part -1, Code of practice for design of tunnel conveying
water- General Design.

ix) IS 4880-1976 Part -2, Code of practice for design of tunnel conveying
water- Geometric Design.

x) IS 4880-1976 Part -3, Code of practice for design of tunnel conveying

water - Hydraulic Design

xi) IS 4880-1971 Part -4, Code of practice for design of tunnel conveying
water- Structural Design of concrete lining in rock

xii) IS 4880-1972 Part -5 Code of practice for design of tunnel conveying

water - Structural Design of concrete lining in soft strata and soil.

xiii) IS 4880-1971 Part -6 Code of practice for design of tunnel conveying

water- tunnel support.

xiv) IS 4880-1976 Part -7 Code of practice for design of tunnel conveying

water- Structural Design of steel lining.

xv) IS 5878-1971 Part -1 Code of practice for construction of tunnel-precision

survey and setting out

xvi) IS 5878-1970 Part -2 section 1 Code of practice for construction of tunnel-

underground excavation in rock-section 1: drilling and balasting

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 xvii) IS 5878-1971 Part -2 section 2 Code of practice for construction of tunnel-
part-II underground excavation in rock-section 2: ventilation, lighting,
mucking and dewatering

xviii) IS 5878-1971 Part -2 section 3 Code of practice for construction of tunnel

conveying water-part-II underground excavation in rock-section 3:
tunneling method for steepy inclined tunnels, shafts and underground
powerhouses

xix) IS 5878-1972 Part -3 Code of practice for construction of tunnel conveying

water-part-III underground excavation in soft strata

xx) IS 11309-1992 rock bolt for mines (cement grouted)-general requirements

xxi) IS 13517-1992 rock bolt-resin type

xxii) IS 5878-1971 part 4 Code of practice for construction of tunnel conveying

water-tunnels supports.

xxiii) IS 5878-1976 part 5 Code of practice for construction of tunnel conveying

water concrete lining

xxiv) IS 5878-1975 part 6 Code of practice for construction of tunnel conveying

water steel lining

xxv) IS 5878-1972 part 7 Code of practice for construction of tunnel conveying

water- grouting

xxvi) IS 15026-2002 Tunneling method in rock masses-guideline

xxvii) IS 9012-1978 recommended practices for shortcreeting

xxviii) BIS Code No. 3764-1992, Excavation Work- Code of Safety

xxix) BIS Code no. 4081-1986, Safety Code For Blasting and Related Drilling
Operations.

xxx) BIS No. 7293-1974, Safety Code for working with construction Machinery.

xxxi) BIS Code No. 4756-1978, Safety Code for Tunneling Work.

xxxii) IS : 13416 (part-I to V) Recommendations for falling material, hazard

prevention, fall preventions, disposal of debris, timber structures, fire
protection

xxxiii) UIC Code no. 779 R “Safety on Tunnel”.

xxxiv) Harbour, Dock and Tunnel Engineering, by R. Srinivasan.

xxxv) Tunnel in weak rocks by Bhawani Singh & R.K.Goel.

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