01 Tunnel Boring Machine TBM Specifications

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION
TUNNEL BORING MACHINE (TBM) SPECIFICATIONS
CONTENTS
Page No
MNW/TBM/
1.
INTRODUCTION ..............................................................................................................................1
1.1 Definitions .................................................................................................................................1
2.
GENERAL ........................................................................................................................................2
2.1 TBM Selection Criteria..............................................................................................................2
3.
CLOSED FACE MACHINES ...........................................................................................................3

3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.
General .....................................................................................................................................3
Cutterhead and Cutters ............................................................................................................4
Cutterhead Drive.......................................................................................................................5
Shield Body, Propulsion and Tailskin .......................................................................................6
Compressed Air Provision ........................................................................................................8
Probing and Ground Treatment ................................................................................................9
Erector ....................................................................................................................................10
PARTICULAR REQUIREMENTS FOR SLURRY MACHINES .....................................................10

4.1 General ...................................................................................................................................10
4.2 Slurry Circulation ....................................................................................................................11
4.3 Slurry Treatment Plant............................................................................................................13
5.
PARTICULAR REQUIREMENTS FOR EPB MACHINES ............................................................16

5.1 General ...................................................................................................................................16
5.2 Screw Conveyor .....................................................................................................................16
5.3 Soil Conditioning .....................................................................................................................17
6.
BACKUP SLEDGES......................................................................................................................17
6.1 General Requirements............................................................................................................17
7.
ALIGNMENT CONTROL ...............................................................................................................18

7.1 General ...................................................................................................................................18
7.2 TBM Guidance Control ...........................................................................................................18
8.
ELECTRICAL SPECIFICATION....................................................................................................19
8.1 General Requirements............................................................................................................19
8.2 Controls and Instrumentation..................................................................................................20
9.
SAFETY .........................................................................................................................................21
9.1
9.2
9.3
9.4
9.5
10.
Regulations .............................................................................................................................21
Work in Compressed Air.........................................................................................................21
Fire Prevention .......................................................................................................................22
Environmental Monitoring .......................................................................................................22
General Requirements............................................................................................................23
MANUFACTURING & COMMISSIONING.....................................................................................23

10.1 General ...................................................................................................................................23
11.
TBM OPERATION & USE .............................................................................................................24

11.1 General ...................................................................................................................................24
11.2 Assembly and Erection ...........................................................................................................24
11.3 Operation and Maintenance ...................................................................................................24
11.4 Primary Grouting.....................................................................................................................26
11.5 Secondary Grouting................................................................................................................27

11.6 TBM Dismantling ....................................................................................................................27

12.
DOCUMENTATION .......................................................................................................................28
12.1 At Proposal Stage...................................................................................................................28
12.2 After Award of Contract ..........................................................................................................28
12.3 Manufacturing Progress Report..............................................................................................30
12.4 After Commencement of Tunnelling .......................................................................................30
ii

1.
INTRODUCTION
1.1
Definitions
1.1.1
Shield is defined as a tunnelling machine comprising a cylinder of metal that is

forced forward through the ground and which protects those working within it who
are excavating the ground at the leading edge. The tunnel lining, if made of
segments, will be erected in the tail of the shield within the tail skin. The shield
will house thrust rams at the periphery which force the shield forward by jacking
from the last completed ring of segments. A means of excavation is mounted
within the shield or alternatively excavation may be by hand tools.
1.1.2
Semi mechanised tunnelling machine means a shield equipped with excavating

machinery (road header, boom excavator, or bucket excavator) which is
independent or semi-independent from the shield and which will allow access to
the face without entry into a separate chamber.
1.1.3
TBM (Tunnel Boring Machine) is a machine comprising excavating machinery

which excavates the full tunnel profile. A TBM may be mounted within a shield
a shielded TBM, or may not have the protection of a shield (e.g. in hard rock), an un-shielded TBM.
1.1.4
A closed face TBM consists of a shielded TBM where the cutterhead can rotate
within an enclosed chamber, which can be pressurised to provide support to the
ground and hydrostatic pressure encountered. This is a pressurised closed face
machine. If the chamber is not pressurised but allowed to remain at atmospheric
pressure it is an unpressurised closed face machine.
1.1.5
An open face TBM is defined as a shielded TBM where there is no pressure

chamber or bulkhead and the material is loaded onto a conveyor at atmospheric
pressure.
1.1.6
Slurry TBM is a closed face TBM used in pressurised mode where the pressure
medium is a slurry, usually bentonite, which is used to carry the excavated
material from the face and is cleaned and re-circulated.
1.1.7
EPB TBM is a closed face TBM used in pressurised mode where the pressure
medium is made up from the ground excavated together with conditioning fluids
which are added as the material is excavated. The conditioning fluid may be
foam, polymer, bentonite or water. The pressure is maintained by releasing the
excavated material slowly through a screw conveyor at a rate consistent with the
TBM advance.
1.1.8
Commissioning refers to the first 200 metres of tunnel construction during which
the equipment is first tested under load and all the operating systems and
instrumentation can be tuned and set up correctly.
268831MC/North-South Transmission Cable Tunnel Contract NS2
MNW/TBM /1

2.
GENERAL
2.1
TBM Selection Criteria
2.1.1
The Contractors proposed TBMs must be able to control ground movements,

including both settlement and heave, under all foreseeable circumstances within
the geological conditions anticipated, as described in the Contract documents,
including mixed face conditions, and thus negate any risk to buildings and other
structures in the vicinity of the tunnel alignment.
2.1.2
The Contractor shall carry out the works using the same type of machine
submitted at Tender stage and shall not be permitted to use any other type of
machine or supplier than those proposed in his Tender, unless accepted by the
Engineer.
2.1.3
The design of the TBM shall be based on inter alia, consideration of the geology
anticipated, the ground and groundwater conditions, the alignment and
dimensions of the tunnel, and the stability of face and surrounding ground during
excavation and prior to placement of the permanent support, minimising ground
loss and consolidation settlement whilst maintaining programmed advance rates
throughout the length of the drive. A detailed description of the ground conditions
can be found in the Geotechnical Interpretative Baseline Report (GIBR). The
GIBR shall be studied for full details of the anticipated geology and hydrogeology
along the alignment.
2.1.4
The Contractor shall demonstrate that his proposed TBM and backup / supply
and spoil removal systems can achieve the advance rates required to meet the
programme dates.
2.1.5
The TBM(s), including all components used, and all associated plant shall be
supplied brand new. The Contractor shall be fully responsible for the selection,
design and supply of the TBMs and all ancillary equipment used, notwithstanding
any of the requirements stated in this specification which shall be suitable for the
conditions anticipated.
2.1.6
The TBM shall be manufactured in units of convenient size, suitable for erection
on site and for dismantling under the site conditions of this Contract. All of the
main components and any single item weighing in excess of 10 tonnes shall have
their weight in metric tonnes clearly marked on them prior to shipping.
2.1.7
The Contractor shall include in his TBM design submission, calculations to show
that the TBM will be able to negotiate the tight horizontal and vertical tunnel
alignment with sufficient clearance between the TBM tailskin and the extrados of
the tunnel lining rings to allow the TBM to turn through all curves on the
alignment without causing damage to the tunnel lining rings.
2.1.8
The TBM shall be designed to construct a suitable precast concrete lining, whose
internal diameter shall be 6.0 metres, 300mm thick and suitable for the geology
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and depths of tunnel anticipated. The Contractor shall consider all construction
tolerances in the design.
2.1.9
Notwithstanding requirements stated elsewhere, it shall be entirely the

Contractors responsibility to select and procure the tunnelling equipment that is
suited for the conditions and will meet schedule and performance and safety
requirements.
2.1.10 The Contractor shall fully acquaint himself with the anticipated geological
conditions. The proposed TBM shall be capable of overcoming all anticipated
conditions while maintaining the required advance rates and face pressures for
control of settlement. Considerations shall be given, but not limited to the
following:
a) Mixed face conditions;
b) Blockages;
c) Abrasivity;
d) Core stones; and
e) Any other conditions that may affect the programme.
3.
CLOSED FACE MACHINES
3.1
General
3.1.1
The TBMs shall be designed and manufactured in conformity with the

requirements of the Standards listed in Clause 9.1.1.
3.1.2
The machine shall have the capability to handle, break up as required and
remove boulders / blocks through the spoil discharge system, whether it is a
crusher and slurry discharge or a screw conveyor, or any other spoil discharge
system without causing blockages to the system.
3.1.3
All closed face machines shall be designed to maintain pressure on the

excavated ground at all times during the process of excavation at programmed
rates and during any period when changing cutters, carrying out any repairs,
during probing, during segment installation and when idle for extended periods.
3.1.4
The machine shall be able to balance the total overburden pressure, including
hydrostatic pressure, and this applied face pressure shall be capable of being
varied as the overburden pressure changes. Face pressure shall be maintained
at 0.1 bar of the required set pressure.
3.1.5
A suitable, dewatering system shall be installed in the shield and ring build area
to ensure that any seepage from the face can be controlled. This should pump to
holding tanks near the rear of the backup from where it can be pumped out of the
tunnel.
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3.2
Cutterhead and Cutters
3.2.1
The cutterhead shall be capable of bi-directional rotation, clockwise or

anticlockwise, and shall only be able to excavate the ground whilst the hydraulic
rams are being actuated. The design shall ensure that the cutterhead can be
retracted back from the unexcavated ground to minimise the risk of the
cutterhead jamming and to facilitate maintenance. Such rearward movement
shall not require rearward movement of the tail shield.
3.2.2
The cutterhead shall incorporate a full face of 19 inch single disc cutters,
arranged with a maximum spacing of 85 mm. These shall be extra heavy duty
grade (long life) cutters (utilizing cutting rings with a minimum hardness of
Rockwell Rc 55) where Granite (GI III) is encountered. They shall be back
loading type capable of being changed from within the cutterhead.
At least 2 gauge roller discs cutting on the same outer most cutting path be
provided to minimise the chance of TBM getting stuck in the rock due to reduced
cutting diameter. In addition a measuring device be provided on the TBM to
detect the amount of overcut to minimise the risk of TBM getting stuck in rock.
3.2.3
The tip of all disc cutters, at its limiting wear criteria shall lead any soft ground
tools fitted by at least 40 mm and the offset ahead of the main cutter head
structure shall be sufficient to allow the excavated material to move freely away
from the face without becoming trapped between the face and the surrounding
cutter head structure.
3.2.4
A high degree of cutter wear is likely on the TBMs. The TBM should be designed
to facilitate the swift changing of cutting tools. In his submission the Contractor
should state how he will minimise this down time and highlight any features he
will incorporate on his TBM to facilitate this, detailing typical expected change
times for gauge, face and centre cutters.
3.2.5
Wear is to be expected to the surface of the cutter head structure, as well as the
buckets or scrapers. These should be extensively protected with abrasion
resisting material (s), which shall have hardness greater than that of the free
silica within the granite matrix. In mechanical terms the hardness shall be equal
or greater than that provided by good quality disc cutters (approx Rockwell Rc 55
minimum).
3.2.6
A system to detect wear to cutting tools, muck collecting bucket and the main
cutter head structure shall be incorporated. A minimum of six wear detectors shall
be provided providing indication in the operators control panel.
3.2.7
The TBM manufacturer is required to carry out a demonstration of the changing

of the cutting tools during factory trials. He should simulate how the cutting tools
will be changed in the tunnel by transferring the cutting tools to the material lock
and through into the cutter head chamber. Cutters from the centre, middle and
periphery of the cutter head should be removed and exchanged with those
transported in. The removed cutters are to be transported out. The manufacturer
shall not use any equipment or working platforms that are not part of the TBM
supply. A full report (written in English and including photographs) is to be
submitted to the Engineer within one month of the demonstration.
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3.2.8
The cutterhead shall incorporate suitable open area to facilitate muck flow.
These openings shall be capable of being closed, hydraulically or by manual
positioning of plates in fitted brackets, for safety reasons during interventions in
unstable ground conditions.
3.2.9
Notwithstanding the requirement of clause 3.2.8, openings in the cutterhead shall

be suitable to allow satisfactory access for face inspections, cutterhead
maintenance and occasional manual removal of excavated materials.
3.2.10 Grizzly bars, or other means, shall be provided to prevent boulders of a size
which cannot be handled by the spoil disposal system, entering the excavation
chamber.
3.2.11 The cutterhead shall have a series of paddles or stirrer bars protruding from
either the rear face of the cutter-head or from the front face of the shield
bulkhead, or both, that are designed and located to prevent excavated material
plugging within the cutter chamber.
3.3
Cutterhead Drive
3.3.1
The cutterhead shall be driven by a variable speed electric or electro-hydraulic

system of sufficient power to excavate the anticipated rock and mixed face
conditions at the required rate. A torque/speed curve for the system shall be
provided.
The system shall include a facility for starting off load prior to
addressing the excavated face. Continual monitoring of cutting torque values
and main drive motor temperatures shall be provided with interlinks to preset
initial warnings and second stage limit shutdown.
3.3.2
A rapid response torque limiting device shall be installed which shall act to
prevent damage to the drive transmission should a cutterhead lockup occur.
3.3.3
The cutterhead drive source and transmission components shall be robust and
capable of completing the contract drive lengths without major overhaul. The
main bearing shall have a design L10 life of 10,000 hours.
3.3.4
The TBM structure shall be so designed so as to allow for the replacement of the
cutterhead main bearing and seal assembly from within the tunnel.
3.3.5
The cutterhead main bearing shall be lubricated from a well proven centralised
lubrication system. Strategic sampling points shall be provided to monitor
lubricant flows, pressures and quality.
3.3.6
The cutterhead main bearing shall be protected and enclosed by a robust and
proven multi-stage seal and labyrinth capable of ensuring internal lubricant
integrity whilst protecting against the ingress of water and excavated fines at the
maximum pressure to be encountered which is anticipated to be in excess of 6
bar. The system shall be safeguarded against overheating and lack of lubricant.
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3.3.7
3.4
The cutterhead shall be fitted with a low speed interlocked inching device capable
of rotating the cutterhead under fine control to obtain accurate positioning for the
purpose of face inspection, cutter tool maintenance or probing.
Shield Body, Propulsion and Tailskin
3.4.1
The circumferential profile of the shield of any TBM supplied by the Contractor
shall be built to a tolerance that ensures the tunnel linings can be built to within
the specified construction tolerance. It shall also be strong enough to avoid
distortion under operational loads during driving and suitable for building the
tunnel linings. The design shall take into account, amongst other things, the type,
density, gradation, strength and abrasivity of the ground.
3.4.2
The machine shall be fitted with a pressure bulkhead capable of withstanding the
maximum total overburden pressure (including hydrostatic pressure, not less than
6 bar), plus an adequate safety margin throughout the life cycle of the TBM with
sufficient wear protection to the acceptance of the Engineer.
3.4.3
A minimum of 6 pressure sensors shall be located on the pressure bulkhead (two

at the crown, two at machine axis level and two at the invert) to monitor and
record the face pressure. Replacement of pressure sensors shall be possible
from the rear of the bulkhead without reducing the face pressure. All sensors
shall be calibrated in accordance with the manufacturers recommendations.
3.4.4
Recessed into the forward face of the pressure bulkhead shall be an adequate
quantity of service penetrations for electricity, water, high pressure air,
dewatering or any other facility including spare penetrations, that may be
required that can be manually operated by maintenance personnel who may be
in front of the pressure bulkhead. The recesses shall have a cover to ensure the
ingress of tunnel spoil does not occur. All services shall be suitably designed for
use during compressed air works.
3.4.5
The TBM shall be articulated to allow for steering along the specified alignment.
Articulation joints shall be provided with a sealing arrangement capable of
withstanding the full hydrostatic head and full overburden pressure. Seals shall
be protected from damage caused by ingress of material during the activation of
the shield articulation. Articulation rams shall be fitted with a mechanism to resist
torque resistance.
3.4.6
At each articulation joint there shall be a sufficient number of lubrication injection

points to the external portion of the shield structure. A non return valve shall be
connected to each injection point to arrest the flow of material from outside the
shield.
3.4.7
The TBM shall include a series of ports in the shield skin to facilitate the
lubrication of the shield/ground interface around the entire periphery of the shield.
The distribution system should be located as near to the cutterhead as practical
and should be fitted with non-return valves to prevent ingress of ground.
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3.4.8
The TBM shall be equipped with thrust rams of sufficient capacity to advance the
machine through all materials encountered at full hydrostatic pressure at a rate
commensurate with the progress rate required by the programme.
3.4.9
Thrust cylinders shall be arranged such that individual rams can be operated
independently during ring building, or in groups for the purpose of steering the
shield. The hydraulic pressure shall be independently variable in each group from
the operator console.
3.4.10 Rams shall be fitted with shoes made from hardwood, polyurethane or similar
material and so arranged that the line of action is through the middle third of the
segment. The shoes shall be dimensioned such that the bearing load does not
exceed that permissible for the segments.
3.4.11 The tailskin shall be fitted with a minimum of three rows of wire brush tail seals,
but preferably four rows in view of the high water head, to prevent the ingress of
water and/or grout between the tailskin and tunnel lining. The tail seal assembly
shall be capable of withstanding the full hydrostatic head and exclude the ingress
of any grout being injected. At least two rows of the wire brush tail seal elements
shall be replaceable from within the shield without exposing the ground during the
drive. An effective tail seal greasing system shall be provided to lubricate the tail
seals continuously from an automatic variable flow and pressure system.
3.4.12 Grout excluder plates shall be fitted to the outer end of the tailskin to prevent
grout migration along the shield towards the face.
3.4.13 The machine shall be designed to enable the void behind the segments to be
grouted continuously and completely from the shield as it is propelled forward
through grout ports incorporated within the tailskin. These shall not be mounted
externally on the machine.
3.4.14 There shall be at least one set of grout ports in each quadrant of the tailskin
circumference, preferably located at or close to the tunnel shoulder and knee
levels. The machine shall have the facility and the capacity to inject grout
simultaneously through at least one grout port in each quadrant.
3.4.15 The grout injection ports should be suitable for the injection of two component
grouts, and the design in each quadrant should incorporate facilities for flushing
the ports and mechanical cleaning. In addition, its design should enable the grout
pipes to any individual port to be cleaned or replaced from within the shield in the
event of a blockage without impairing the performance or preventing the use of
any other grout port.
3.4.16 Spare ports should be incorporated to ensure that at least one grout port in each
quadrant of the shield shall be operational and available for grouting at all times
during shield advancement.
3.4.17 Grout pressure and flow rates shall be maintained at all times whilst the shield is
advancing. Pressure shall be measured at the point of injection. The TBM shall
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incorporate automatic systems for monitoring, controlling and recording the

volume and pressure of the grout being delivered to the tail void.
3.4.18 The machine shall have an anti-roll device details of which shall be accepted by
the Engineer prior to the commencement of tunnelling works.
3.4.19 The machine design shall permit removal back to the launch shaft of the machine
from within the shield, which may be left in place at the completion of the tunnel
drive.
3.5
3.5.1
Compressed Air Provision

Cutterhead interventions will be necessary on a regular basis for the purpose of
cutterhead inspection and maintenance and for cutter changing. Some of these
interventions may be in conditions where the hydrostatic water head above the
crown of the TBM is above 40 metres. In view of the fact that current regulations
limit the use of compressed air to 3.5 bar, the Contractor shall submit his method
of statement for the Engineer review and acceptance prior to such intervention
being carried out. The method of statement may include any, or a combination of
the following:
1. Ensuring that the TBM stops in an area of treated ground
2. Complete or partial treatment of the ground to minimise ground water flow
combined with lower compressed air pressures
3. Application to the Commissioner for Workplace Safety and Health for
exemption in order to utilise pressures higher than 3.5 bar
4. Only partial emptying of the face to reduce the air pressure required
5. Allowing minimal seepage from the face to facilitate the use of lower
pressures. This would require pumping capability within the TBM
6. In extreme situations saturation diving techniques may be required for
prolonged entries at higher pressures.
To facilitate any or all of these techniques the TBM should include the following
features.
Airlocks see clauses 3.5.2. to 3.5.5.
Probing and drilling arrangements see clauses 3.6.1 to 3.6.4.
Provision for adequate platforms in the cutterhead chamber see clause
3.2.7.
Provision for adequate pumping and dewatering from the TBM see clause
3.1.5.
3.5.2
All airlocks shall conform to BS EN 12110:2002 or equivalent international

standard. See also requirements of clause 9.2 below.
3.5.3
The TBM shall incorporate a twin air-lock each with two compartments for man
access to the cutterhead and face, with the main compartment sized for at least 3
persons. The air lock should be designed to suit the maximum intervention
pressure, consistent with the alignment and depth selected by the
contractor. The contractor should state in his offer the pressure for which the
airlock will be designed. If this pressure is in excess of 6 bars, the requirements
of Clause 3.5.6 will apply. The inner compartment shall be able to accommodate
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a 1.8-metre long stretcher and two attendants. Doors shall be capable of being
opened without manipulation of the stretcher and patient.
3.5.4
The airlocks shall be fitted with all the necessary provisions to enable
decompression using oxygen or mixed gas mixtures (e.g. Heliox, Nitrox or Trimix)
to be employed. Refer to the documents mentioned in Clause 9.2.3.
3.5.5
A material lock shall also be provided independently of the personnel air locks
and this shall be located at a convenient point above horizontal axis for the
transport of maintenance tools and disc cutters etc. into the pressure chamber.
3.5.6
If the Contractor includes saturation diving techniques as one of his contingency

proposals for interventions or access to the cutterhead when tunnelling at the
deep level, the air lock should be manufactured with an outer flange around the
access door opening to enable a Transfer under Pressure (TUP) Shuttle to
couple safely to the lock and allow transfer of personnel at pressure. If such
procedures are considered possible, a fully detailed method statement, following
the principles laid down in the document listed in Clause 9.2.4 is to be agreed
with the Engineer.
3.6
Probing and Ground Treatment
3.6.1
The machine shall be designed for and equipped with a supplemental ground
stabilisation system. The machine shall be designed to allow forward drilling
through the cutterhead and shield for the purpose of probing ground conditions to
carry out ground treatment to the face and surrounding ground. The proposed
system shall comprise of regularly spaced grout sleeve pipes built into the shield
skin for grouting the ground ahead of the tunnel axis. They shall be fitted with
suitable valves and located such that there is space for the use of blow out
preventers. This system shall comprise a minimum of 16 No regularly spaced
grout sleeve pipes built into the shield skin for grouting the ground ahead of the
tunnel face. They shall be inclined at an angle of approx 5 from the tunnel axis
and be fitted with suitable valves and located such that there is space for the use
of blow out preventers.
3.6.2
In addition provision for drilling straight ahead through the bulkhead and
cutterhead shall be provided.
3.6.3
These access ports may be used for ground stabilisation around or ahead of the
TBM or for probe drilling. The capability to recover 38mm rock cores should be
provided.
3.6.4
Ground stabilisation ahead of the TBM is considered an important tool in view of

the depth of the tunnel and the geological conditions. A minimum of two drilling
machines capable of probing or drilling for ground treatment shall be provided
either on the TBM or close behind on the back up gantries. They should be
capable of drilling a minimum of 50 metres ahead of the face and kept in working
order at all times. The drilling/grouting equipment shall be permanently mounted
in the machine and be operational within 2 hours of any requirement to drill/grout.
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3.7
Erector
3.7.1
The machine shall be equipped with a tunnel lining erector system capable of
placing each lining segment safely into its final position along the periphery of the
ring being erected. The erector and the tail skin / seal configuration shall be
arranged such that damaged segments are capable of being removed from an
assembled ring within the first 500mm of the TBM advance.
3.7.2
The erector shall be controlled from a radio controlled pendant such that the
operator has a clear unobstructed view of all of the plant that he is operating at all
times. During ring building the controls for the shield rams shall be transferred
from the TBM operator cabin to this pendant.
3.7.3
The erector shall be provided with the facility to lower the segment from top dead
centre to bottom dead centre location, for safety, in the event of mains power
failure whilst ring erection is in progress.
3.7.4
Ladders and platforms fitted with toe boards and safety harness connections
shall be provided to enable operatives to reach bolt connection holes. Platforms
shall be fitted with appropriate safety systems to prevent collision with the
erector.
3.7.5
The segment erector and segment feeder shall be fitted with audible and visual
alarms that activate prior to movement.
3.7.6
If a vacuum type lifting pad is proposed, design calculation shall assume 80%
vacuum for all vacuum devices. Mechanical shear pins shall be incorporated into
the design. In the event of power failure, the vacuum system shall be able to
hold the heaviest segment for 20 minutes.
4.
PARTICULAR REQUIREMENTS FOR SLURRY MACHINES
4.1
General
4.1.1
Slurry TBMs operating in fractured and weathered rock may suffer from excess
blockages within the cutter head and in the pipework. The contractor should
provide a method statement of how such blockages will be minimised and
cleared when they do occur.
4.1.2
Slurry inlet pipes shall be arranged to enable jetting near the invert to prevent
settling of material and to act in conjunction with the stirrer bars mentioned in
3.2.11 to minimise blockages.
4.1.3
Control of face pressure in the slurry should be within 0.1 bar at all times. Any
fluctuation in pressure beyond this limit shall initiate an audible and visual alarm
in the TBM operators cabin and both the Contractors tunnel office at the surface
and the Engineers office. The slurry seal in the slurry chamber shall have a
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structure capable of withstanding a slurry pressure that is at least three (3) times
the maximum planned face pressure.
4.1.4
The Contractor shall ensure that the spoil transportation system and other
support services to the TBMs have sufficient capacity to ensure that the proposed
TBM tunnelling rates can be maintained in all the anticipated ground conditions to
achieve the programme key dates and meet the Schedule of Timing.
4.1.5
Experience show efficient slurry discharge reduces blockages in the cutter head
chamber increasing efficiency and reducing unplanned interventions. The
Contractor is advised to pay special attention to the routing of the slurry
transportation pipe work to reduce unnecessary bends through the TBM.
Location of primary pumps and crushers should be selected to improve the
efficiency.
4.1.6
The positions at which the slurry feed and, discharge pipes are mounted on the
bulkhead shall be determined in consideration of the slurry flow within the slurry
chamber and discharge of the excavated soil. Slurry discharge pipes shall be
provided in two or more locations as a precaution against blockage.
4.1.7
An agitator shall be attached at the bottom of the slurry chamber to prevent soil
from settling while not excavating.
4.2
Slurry Circulation
4.2.1
Design of the slurry circulation and control system should take into account, inter
alia, properties of the excavated material and the properties of the required slurry
to be pumped to the TBM. Flows, velocities and consequent pipe sizes and
slurry densities shall be designed to maintain suspension and minimise
settlement whilst minimising abrasion and power consumption. The Contractor
shall supply calculations supporting his design.
4.2.2
Slurry pipework on the TBM shall be arranged to optimise the slurry flow through
the excavation chamber, and to minimise clogging at the discharge entrance.
Provision shall be made to break up balls of clay or other fine materials before
they enter the discharge pipes.
4.2.3
The TBM shall be capable of preventing any over pressurisation of slurry in the
cutter head chamber by automatically cutting off the slurry feed and initiating a
pressure release valve to restore the pressure to that specified.
4.2.4
It is anticipated that some large pieces of rock may enter the cutterhead
chamber. The Contractor shall indicate how these would be dealt with. A rock
crusher shall be incorporated into the circuit in order to break down large
boulders and assist their passage through the pipes and pumps.
4.2.5
The rock crusher shall have sufficient capacity to crush any boulders, without
impeding the advance of the machine. It shall be arranged so that it can be
repaired and maintained during the drive.
MNW/TBM /11

4.2.6
The slurry circulation circuit must incorporate a bypass close to the TBM so that
steady circulation can be established before the slurry is allowed to enter the
TBM. Bypass lines on the surface and at the shaft bottom shall also be included
in the circuit.
4.2.7
Facilities to reverse circulate the slurry flow in the pipework close to the TBM
shall be included in order to assist the clearing of blockages. Alternative slurry
supply pipes to the cutterhead chamber shall be fitted including jetting nozzles, to
enable blockages and clogging to be minimised and mixing of spoil in the
chamber to be optimised.
4.2.8
Slurry pipes shall extend as the TBM and backup system advance. It is foreseen
that this is by means of telescopic pipes or flexible hoses situated at the rear end
of the backup system. Adequate means of supporting and operating these,
including the storage of additional pipe lengths and the placement of gate valves
at regular intervals shall be provided.
4.2.9
High vibrations and movement of discharge pipes shall be avoided. The pipes
shall be anchored sufficiently to avoid the risk of rupture.
4.2.10 Booster pumps shall be installed along the tunnel at suitable locations to ensure
optimum slurry flow rate. A minimum of one spare booster pump for each tunnel
together with all associated valves and controls shall be kept at site.
4.2.11 Pipes shall be installed without loss of pressure in the face and with the minimum
loss of slurry into the tunnel. A means of collecting and disposing of all slurry
spilled during the pipe extensions shall be provided.
4.2.12 Pipe work shall wherever possible be laid in straight runs to minimise friction
losses and wear. Where bends are unavoidable, these shall be heavily
reinforced to provide extra wear protection, and be easily replaceable. Pipe work
should be thick walled and have its thickness checked regularly by the contractor,
who should also periodically rotate straight lengths of pipe.
4.2.13 Wear due to abrasion in the discharge pipe and components is expected to be
high. Abrasion resistant materials should be used wherever practicable. All pipe
joints shall be of the raised flange S-type so there is no reduction in wall
thickness along the length of the pipe. Recessed flange G-type pipe joints shall
not be used.
4.2.14 Flow meters and density meters shall be provided on both supply and discharge
pipelines to enable the total quantity (flow rate and density) of solids excavated to
be monitored and recorded continuously while the TBM is cutting at the face.
4.2.15 The machine design shall make provision for the crusher to be checked at the
start of each shift and cleaned where appropriate.
4.2.16 The slurry feed and discharge pipes shall be controlled so that the flow volume
and pressure can be adjusted before and after cutting, to ensure the stability of
the face.
MNW/TBM /12

4.2.17 The slurry transportation system shall include a facility that links the slurry
pressure sensors and the slurry feed and discharge pump, to allow a constant
slurry pressure to be maintained at the cutting face. There shall be a facility that
automatically adjusts the pressure when fluctuations in the slurry pressure at the
cutting face are detected.
4.2.18 Gate valves shall be installed at regular intervals along both the feed and
discharge slurry pipes.
4.2.19 The pressure control system shall be relayed to a monitor on the surface for
continuous monitoring. Provision shall be made to enable pressure to be adjusted
from the surface at times when the machine is not operating.
4.3
Slurry Treatment Plant
4.3.1
The Slurry Treatment Plant (STP) is deemed an integral part of the slurry TBM
design. The Contractor shall include in his TBM design submission full details of
his proposed STP, together with details of the slurry pumps and pipelines.
4.3.2
The slurry treatment plant (STP) and its support system shall be designed by
specialists with experience in the operation of this type of equipment and the
design shall be endorsed by the TBM manufacturer. The design shall clearly
demonstrate:
a) Operation and control of the slurry treatment plant in conjunction with the
TBM as one complete system;
b) Consideration of the planned efficiency of separation of each stage (e.g.
primary, secondary, fines) of the separation process and the particle size
grade separation at each stage to suit the anticipated ground conditions.
This shall be specified in terms of weight of dry material processed per
hour and the plant operational efficiency, which shall be based on past
experience and not be taken as 100%;
c) The ability to provide slurry at the required density for circulation to the
TBM;
d) Compliance of the STP with the statutory requirements for noise and
vibration.
4.3.3
The STP shall have sufficient capacity for all stages of treatment to match the
programmed advance rates for all the TBMs excavating through the most
onerous anticipated ground conditions without causing any delays to the
advancing TBMs. The plant shall be designed to facilitate routine maintenance
without requiring TBM advance to halt and shall be capable of being expanded to
increase operational capacity should the need arise. Such expansion or any
additions or modifications to the STP shall be approved by the STP supplier and
accepted by the Engineer.
MNW/TBM /13

4.3.4
Slurry treatment is required to have sufficient holding tank capacity to meet the
requirements for each TBM. This capacity includes sufficient capacity for slurry /
water being treated before discharge into the public drains as well as sufficient
capacity for holding of fresh hydrated bentonite. For avoidance of doubt, holding
and mixing tanks shall be separate.
4.3.5
The STP shall be monitored and controlled from a central control cabin which
shall as a minimum have a direct telephone line to the TBM control cabin for the
sole use of the TBM operator and STP plant operator. The STP central control
cabin shall be connected to the TBM slurry circuit monitoring system with a
suitable display acceptable to the Engineer. The STP operator shall be capable
of controlling all aspects of the work from within the control cabin including the
transportation and treatment of the slurry.
4.3.6
All STP main components shall be monitored real time with visualization and data
acquisition in the STP control room and the Engineers office. Information to be
monitored and recorded is, inter alia,
Flows into and through the separation plant (t/hr)

Weight (t) and volume of solids removed (m3)
Volumes of fresh slurry added to the system (m3)
Volumes of slurry transferred to secondary treatment (m3)
Amount of flocculent used
Weight of solids and water recovered from secondary treatment and
removed (t)
Levels of active and storage tanks (m)
Density of slurry in the active tank (t/m3)
The system shall produce a printed report to be submitted to the Engineer daily.
4.3.7
It is envisaged that one central control room for monitoring both the TBM
operating parameters and the STP parameters will be established in the
Contractors office. This will allow for the proper control and integration of the two
(2) critical systems.
4.3.8
The STP shall be suitably designed with testing points so that-routine testing at
various stages of separation can be safely and easily carried out with minimum
time.
4.3.9
A test laboratory shall be included as part of the surface installation. This shall
have equipment for measuring density, and sand content of slurries, apparent
and plastic viscosities, together with the yield point of slurries, gel strengths, pH
levels, filter cake formation, fissure penetration and other routine slurry tests.
4.3.10 Slurry supplied to the TBM from the treatment plant shall have a density to suit
the prevailing ground conditions being excavated. The density of the slurry
supplied to the TBM shall never be greater than 1.15 and the STP should have
capacity to remove sufficient material to ensure that this density can be
MNW/TBM /14

maintained without impairing the advance rate of the TBM in all ground
conditions.
4.3.11 The transportation of the discharged spoil away from the work site shall be by
means that prevents spillage in either fluid or solid form. The Contractor shall
assess the traffic conditions and the impact to the existing transportation system.
Measurement of the amount of spoil shall be carried out by the Contractor.
4.3.12 Slurry and other water discharged from the works shall be passed through
filtering facilities before being discharged. Any filtered water that is discharged
into water courses or sewers shall be in accordance with the relevant Singapore
Regulations and Standards.
4.3.13 Noise from STP operation and spoil removal activities may be excessive and can
cause inconvenience to residents in nearby buildings. The Contractor shall
comply with the NEA regulation on noise control (refer to General Specification).
If necessary, the Contractor shall provide full acoustic enclosures/barriers over
and around STP and muck-pit areas to contain the noise and prevent
disturbance.
4.3.14 The STP shall be suitably designed and operated in a manner to ensure that a
slurry density appropriate to the prevailing ground conditions is continuously
supplied to each TBM. The TBM operator shall be provided with a CCTV link to
enable him to observe the STP primary screens for the effects of variation in TBM
penetration and cutter head speeds and to ensure maximum primary screen
separation.
4.3.15 The STP and TBM monitoring systems are to be compatible to allow the overall
control of slurry volume in the active circuit for each TBM. The real time volume is
to be displayed on the STP visualization, data logged and linked to an alarm to
be activated if the volume varies by more than a predetermined value agreed with
the Engineer.
4.3.16 Materials separated at primary, secondary and final stages of separation are to
be segregated prior to removal from site in bins to facilitate identification of a
change in ground conditions.
4.3.17 Slurry feed and discharge density shall be monitored as near to the TBM cutter
head as possible as well as at all appropriate separation stages of the STP.
MNW/TBM /15

5.
PARTICULAR REQUIREMENTS FOR EPB MACHINES
5.1
General
5.1.1
The EPB TBMs shall be equipped with a rotary joint to supply soil conditioning
materials to the cutterhead, a screw conveyor and a belt conveyor for muck
disposal.
5.1.2
Belt conveyors shall be fitted with scrapers and be suitable for wet, abrasive and
sticky material. Conveyor belting shall be heavy duty, suitable for underground
use and made from materials which reduce the fire risk and toxic fume risk
5.1.3
The conveyor belt shall incorporate an automatic material weighing system to

measure the weight of material excavated on a continuous basis. This
information to be recorded in the TBM data logging system.
5.2
Screw Conveyor
5.2.1
The screw conveyor shall be of a sufficient length to allow for adequate pressure
dissipation along its length whilst maintaining an effective plug to balance the
ground and ground water pressures that will be encountered.
5.2.2
Calculations with supporting analysis shall be provided with the final design
submission to demonstrate that the capacity, power and length of the screw
conveyor is sufficient.
5.2.3
The discharge of the screw conveyor shall be installed with a closing mechanism
that can withstand a pressure of at least 25% greater than the maximum
expected head of water. It shall be fitted with an accumulator which automatically
closes the gate in the event of a power failure or when the face pressure falls
below a pre-set value.
5.2.4
The screw conveyor shall be capable of being withdrawn and a water tight
guillotine gate closed on the bulkhead to allow maintenance without loss of face
pressure.
5.2.5
To protect against excessive abrasion, replaceable abrasion resistant wear parts

shall be fitted at the entrance to the screw conveyor casing and on the tips of the
first three pitches of flights.
5.2.6
The screw casing shall be fitted with injection points for conditioning agents and
with earth pressure monitoring cells.
MNW/TBM /16

5.3
Soil Conditioning
5.3.1
The machine shall be equipped with a suitable soil conditioning system to

condition the material as it is excavated. It should be capable of supplying
bentonite, foam and polymers to the cutterhead and to the bulkhead and screw
conveyor during excavation.
5.3.2
There shall be a sufficient number of injection ports in the cutterhead, spaced

proportionately to the swept area, to inject the additives. Each port shall have its
own individual feed line through a rotary coupler, and fed from independent foam
generation units. Provisions should be included for clearing or replacing any
blocked lines and/or ports from inside the TBM.
5.3.3
The operation and control of the soil conditioning plant shall be from within the
TBM operator panel and volumes and pressures of additives injected shall be
monitored and recorded.
5.3.4
The calculations and detailed design of the soil conditioning system shall be
provided during the design stage of the TBM supply.
6.
BACKUP SLEDGES
6.1
General Requirements
6.1.1
A high degree of wear is to be expected for the material transport system. All
components designed to transport the excavated material shall be manufactured
to provide an abrasion resistant surface to minimise replacement and / or
maintenance.
6.1.2
The towing load in the connection between the TBM and the trailing backup shall
be continuously monitored. When the tow force exceeds 110% of the maximum
designed tow force an audible/visual alarm shall be activated in the TBM
operators cabin. When the towing load reaches 120% of the designed tow force
the thrust ram pump shall be deactivated automatically to prevent the TBM from
advancing further.
6.1.3
A physical barrier shall also be located at the last TBM trailer to separate and
protect the workers in the shield from moving railway equipment. The barrier
should be in position at all times and be raised manually by the loco driver when
a train wishes to enter the TBM backup.
6.1.4
Adequate facilities shall be provided for the extension of all services to the TBM
at the rear end of the last trailer.
6.1.5
Design of the backup trailers shall allow for them to be removed at the end of the
drive by withdrawing back along the constructed tunnel.
6.1.6
There shall be a clear and unimpeded means of egress along the full length of
the back up at all times from the erector to the tunnel walkway.
MNW/TBM /17

7.
ALIGNMENT CONTROL
7.1
General
7.1.1
7.2
For general survey requirements for tunnelling works refer to M&W Specification.
TBM Guidance Control
7.2.1
A suitable and proven guidance system shall be installed on the TBM to provide
the necessary survey data and lining erection information for accurate control and
steering of the machine.
7.2.2
A tunnel machine guidance system is mandatory. The machine shall not advance
without a fully operational guidance system.
7.2.3
The guidance system shall produce a comprehensive real time read out of the
current shield position and attitude and of the predicted position at a set distance
ahead. The system shall incorporate a laser theodolite, distomat and the
necessary laser target, mounting beam etc. which shall form an integral part of
the TBM. Monitoring information from the TBM guidance system shall be visible
in the TBM operators control cabin and in the in the Engineers office on the
surface. All data is to be recorded digitally for submittal to the Engineer both as a
hard and electronic copy.
7.2.4
Prior to the commencement of tunnelling and then throughout the tunnel drive the
Contractor shall establish and implement survey and alignment control
procedures. During each shift the Contractor shall survey the position of the
tunnelling machine and verify the guidance system readout is correct.
7.2.5
The fully integrated system shall comprise at least, measuring equipment,

software, PC and display. The design tunnel alignment entered into the system
shall be password protected. The display shall be updated every few seconds
and provide the operator with the necessary graphical and numerical information.
The system shall compute the precise machine position and offsets from the
Design Tunnel Alignment (DTA). The following information shall be displayed:
a) Cumulative ring number from start of drive;
b) Chainage;
c) Pitch and roll;
d) Look up (plumb to DTA);
e) Lead (square to DTA);
f) Line and level;
g) Prediction of shield position at 10 meters ahead of current position;
h) Articulation angle (where applicable).
The guidance system shall be capable of determining the 3D coordinated
position of the tunnel machine from the proven survey control in the tunnel to an
accuracy of 2mm. All guidance system parameters, input, output and reports
shall be made available to the Engineer in softcopy format (e.g. Excel or similar).
MNW/TBM /18

8.
ELECTRICAL SPECIFICATION
8.1
8.1.1
Electrical equipment shall conform to the following standards
BS 6164:2001 Code of Practice for safety in tunnelling in the construction

industry.
BS EN 12336:2005 Tunnelling machines. Shield machines, thrust boring
machines, auger boring machines, lining erection equipment. Safety
requirements.
1989 Electricity at Work Regulations taking into account Mines Regulations
section where applicable.
The BS 7671: 2008 IEE Wiring Regulations Regulations for Electrical
Installations, 17th Edition
BS 5304:2005 Safety of Machinery.
BS 7430: 1998. Earthing.
BS EN 60204:2006 Electrical Equipment for industrial M/Cs.
BS 7375: 2010 Distribution of Electricity on Construction sites.
Other relevant BS Standards for equipment, workmanship and testing
Singapore Standards CP5 and CP16 as appropriate
Workplace Safety and Health (Construction) Regulations 2007, Part V,
Electrical Safety
8.1.2
All cable shall be LSOH type. PVC cables shall not be permitted.
8.1.3
Pilot and earth monitoring of power supply cables shall be required.
8.1.4
All backup trailers shall be securely bonded together with an earth link which
shall not be smaller than the largest current carrying conductor.
8.1.5
Power factor correction equipment shall be installed to ensure a minimum PF of

0.9 lagging.
8.1.6
All electrical enclosures shall be protected to IP55 as defined in BS EN 60529.

Where this is not practical, for example in the case of power transformers, a lower
IP rating may be used provided the enclosure is in turn contained within a
pressurised cabinet providing adequate additional protection.
8.1.7
Gland entry to enclosures shall be bottom entry. Where this is impractical and
side entry is used, a water cover must be fitted. Top entry shall not be permitted.
MNW/TBM /19

8.2
Controls and Instrumentation
8.2.1
The machine shall be equipped with an air-conditioned control cabin. The

monitoring and control instrumentation shall be grouped in suitable panels within
the control cabin. The cabin shall be smoke/fire proof.
8.2.2
The criteria that shall be monitored and available for the TBM operator to access
in the control cabin shall include, but not be limited to, the following data. It shall
also be available on the data logging system.
a)
b)
c)
d)
Start and finish time of the excavation stroke;

Start and finish time of the ring erector operation;
Shield position and attitude for each ring;
Stroke number, chainage and guidance systems predicted of the next ten
strokes after each build;
e) Rate of advance of TBM and stroke average rate of advance;
f) Numbers of thrust cylinders, location and pressures used during the stroke;
g) Extensometer readings of thrust cylinders at the start and end of the stroke;
h) Articulation cylinder position at the start and the end of the excavation stroke
(articulation angle);
i) Amount of TBM roll at start and end of the excavation stroke;
j) Cutting direction, rotation speed, and pressure/torque of cutterhead;
k) Main bearing axial force;
l) Main bearing lubrication temperature monitored at exit point if re-circulatory
oil, or thermocouple against bearing if grease lubricated;
m) Electrical current consumed by each TBM motor;
n) All earth pressure sensor readings throughout the excavation stroke for cutter
chamber;
o) Volume and pressure of grout injected per stroke (pressure shall be
measured at the point of injection. Pressure and volume shall be monitored
and recorded to an accuracy of not less than two decimal places);
p) Quantity of tail grease consumed per shift;
q) Gas detector sensor readings and alarm activation system;
For EPB Machines
a) Volume, rate of addition, type and location of soil conditioning added per ring
and the cumulative amount per shift with the concentration value;
b) Speed and torque of screw conveyor ;
c) Earth Pressure in the screw conveyor;
d) Volume and mass of material on the belt ;
For Slurry Machines
a)
b)
c)
d)
e)
f)
g)
Display and adjustment of the slurry pressure at the cutting face;

Display and adjustment of the feed slurry pressure;
Display and adjustment of the feed, and discharge slurry flow volume;
Display of the feed and discharge slurry density;
Volume of materials excavated per ring of advance;
Display of feed and discharge slurry pump operating conditions;
Volume of slurry leakage when the machine is stationery.
MNW/TBM /20

8.2.3
The data logger shall be linked to a colour monitor display in the Engineers
office. Each machine shall have its own dedicated colour monitor. The data
logger shall display and record information in real time and shall have the facility
to store all accumulated data from the tunnel drive and to read and display past
data. All data loggers and ancillary equipment shall be provided by and
maintained fully operational throughout the drive by the Contractor. Each data
logger computer shall be connected to a colour printer. The Contractor shall
provide all necessary peripherals and consumables necessary for the display and
printouts. The display monitor(s) and printer(s) shall be sited in the Engineers
office. All data loggers and ancillary equipment shall be fully operational at all
times and shall, be maintained by the Contractor.
The information on the data logger, which is available to the Engineers Office
system, shall be made available on a secured website for Engineer monitoring
purposes.
8.2.4
The machine shall be equipped with acceptable device or devices from which the
weight and volume of material excavated can be monitored and recorded
automatically in real time. These shall be located where they are least affected by
vibration, roll and tunnel curvature. The device shall be synchronized with the
excavation cycle such that it is only activated when the TBM is excavating. The
measured quantity shall be displayed in the control cabin and in the Engineers
office, both on a ring by ring basis and as a rolling 10 ring average. An audible
and visual alarm shall be incorporated in the control cabin which shall be
activated if the measured volume exceeds a pre-determined quantity related to
machine advance.
9.
SAFETY
9.1
Regulations
9.1.1
The design and manufacture of the TBM and back-up systems shall make
adequate provision for the safety of the workmen and the application of safe
methods of tunnelling and shall comply with all relevant British, European and/or
Singapore Standards and Codes of Practice relating to safety including, but not
limited to:a. BS 6164: 2001 Code of Practice for Safety in Tunnelling in the Construction
Industry;
b. BS EN 12336: 2005 Tunnelling Machines - Safety Requirements;
c. BS EN 12110: 2002 Tunnelling Machines-Air Locks-Safety Requirements.
9.2
9.2.1
Work in Compressed Air

It is envisaged that the TBM personnel will work in compressed air conditions
during cutter head intervention. Working in compressed air poses occupational
health and safety risks. Only competent personnel shall be permitted to work
under compressed. In addition, the Workplace Safety and Health Guidelines for
MNW/TBM /21

Compressed Air Works, 2010, published by the Workplace Safety and Health
Council shall apply.
9.2.2
See also the requirements of Clause 3.5.
9.2.3
For working in Compressed Air the following documents and guidelines should be
followed:
a. The Work in Compressed Air Regulations 1996(UK);
b. HSE L96 A Guide to the Working in Compressed Air regulations (1996) (UK);
c. An addendum to "A guide to the Work in Compressed Air Regulations 1996"
giving Guidance on OXYGEN DECOMPRESSION and the use of Breathing
Mixtures other than Compressed Natural Air in the Working Chamber.
d. Workplace Safety and Health (Construction) Regulation 2007
9.2.4
In addition to the above, for working in pressures above 3.5 bar, the following
document is currently being prepared jointly by International Tunnelling
Association and the British Tunnelling Society
Guidelines for Good Working Practice in High Pressure Compressed Air
This should be available by the end of 2011 and shall be followed as appropriate.
9.3
Fire Prevention
9.3.1
Provision shall be made throughout the length of the TBM and back-up
equipment for the detection and suppression of fires. This shall include
Automatic fire detection to sound an alarm in the TBM operators cabin
and on the back up
Manually operated sprinkler system for foam or powder over high risk
areas such as hydraulic power packs;
Automatic operation of inert gas suppression to electrical cabinets;
Hand held extinguishers provided with colour coded covers in suitable
locations;
The provision of a water curtain sited at the trailing end of the TBM
backup.
9.3.2
The fire prevention system shall be maintained in an efficient operating condition

at all times.
9.4
9.4.1
Environmental Monitoring
All TBMs shall be equipped with gas monitoring sensors, which shall be located
at appropriate locations along the TBM including the screw conveyor discharge
on EPB machines, slurry pipe extension area on Slurry TBMs, the TBM bulkhead
and the ring building area on all machines. All sensors shall be connected to an
audible/visual alarm system located throughout the tunnel and at the surface.
The sensors should detect potentially hazardous gases including but not limited
to oxygen deficiency, methane, carbon dioxide and carbon monoxide. In addition
MNW/TBM /22

the gases NOx and H2S should also be monitored if it is considered there is a risk
of them being present.
9.4.2
9.5
The alarm shall automatically activate at gas levels exceeding the permissible
exposure levels as defined in the Workplace Safety and Health (Construction)
Regulations 2007 and BS 6164: 2001 Code of Practice for Safety in Tunnelling in
the Construction Industry.
9.5.1
The Contractor shall use synthetic hydrochloric fire resistant (type HFDU) fluids
on all systems of the machine and back-up equipment so as to minimise the risk
of an oil fire.
9.5.2
Sufficient, non slip foot steps and safety harness attaching points adjacent to all
locations in the cutterhead where cutter changing may occur shall be provided to
ensure personnel are adequately protected. Either a mechanical device to
support the mass of any cutter assembly greater than 30 kg, or attachment
points, for personnel to connect hand operated lifting devices shall be provided.
9.5.3
The material used for any conveyor belting used shall be non-combustible and
low smoke emission type.
9.5.4
All moving machinery installed on the TBM shall be appropriately guarded. Guard
design should allow for routine maintenance requirements. Audible/visual
movement warning signals shall be installed together with an emergency stop
system at locations to be agreed with the Engineer. The conveyor belt
emergency isolation system shall include pull-wire interruption along the entire
length and on both sides of the belt.
9.5.5
The Contractors support services shall be compatible with the design of the
TBMs (Contractor shall obtain the endorsement of machine supplier), its intended
spoil handling system and the ring erecting system to ensure that work can be
carried out efficiently and safely.
10.
MANUFACTURING & COMMISSIONING
10.1
General
10.1.1 Before the machine is dispatched to the tunnelling site, it shall be completely
assembled in the manufacturers factory with all necessary equipment installed
so that it is in working order for inspection and checking by the Engineer. Sample
segments shall be available to demonstrate the segment erection procedure. The
assembled TBM shall be tested and commissioned before shipment to site.
10.1.2 The Contractor shall supply all necessary information to the Engineer, including a
programme of manufacture and testing, to enable him to inspect the machine at
MNW/TBM /23

the manufacturers factory to ensure that the design and manufacture are in
accordance with the specification and to enable him to observe the factory tests.
The Contractor will be given one week notice of any visits required and he shall
ensure that suitable English speaking technical staff from either the Contractor or
his TBM supplier are available to accompany the Engineer and his
representatives.
10.1.3 A complete list of spare parts, wear items and consumables shall be
established for the TBM and be submitted to the Engineer prior to Testing of the
TBM in the factory.
11.
TBM OPERATION & USE
11.1
General
11.1.1 The Contractors support services shall be compatible with the design of the
TBMs, its intended spoil handling system and the ring erection system to ensure
that the work can be carried out efficiently and safely.
11.2
Assembly and Erection
11.2.1 When delivered to site the machine shall be erected in the launch chamber or
start shaft to the required grade and line, and to maximum tolerances of 6 mm
in external diameter and 20 mm in external circumference or as specified by the
manufacturer.
11.2.2 Details of the TBM erection and procedures for launching the TBM from the
underground launch chamber shall be provided to the Engineer.
11.2.3 The design of the TBM and thrust frame together with the support frame for the
temporary shove rings shall be carried out by a Professional Engineer (PE)
registered with the Professional Engineers Board and shall be submitted to the
Engineer for acceptance. The TBM cradle, thrust frame and support frame for the
temporary shove rings shall be inspected and endorsed by the PE prior to loading
and unloading.
11.2.4 A detailed method statement shall be submitted for acceptance prior to the
installation and removal of the TBM cradle, thrust frame and the support frame for
the temporary shove rings.
11.3
Operation and Maintenance
11.3.1 The Contractor shall operate and maintain the machine to the satisfaction of the
Engineer and in accordance with the manufacturers recommended operating
and maintenance instructions.
MNW/TBM /24

11.3.2 The Contractor shall store on site critical replacement parts and maintenance
materials, to ensure that the TBM is not delayed waiting for delivery of
components. The Contractor should submit to the Engineer a list of such
components that will be stored on site, and these should include (but not be
limited to) such items as
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Sufficient complete sets of discs, picks, cutters and scrapers

Nonstandard hydraulic rams, hydraulic hoses and components
One spare PLC card for each electronic component
Other electrical consumable components
One full set of tail seal brushes
One full set of earth/fluid pressure sensors
Spare impellors and casings for slurry pumps (for slurry TBM)
Screens and cyclone spigots for STP(for slurry TBM)
Conveyor belting, rollers, bearings and bolts (for EPB TBM)
Wear components for Screw conveyor(for EPB TBM)
11.3.3 The TBM operators and the Contractors chief mechanic(s) shall be trained and
certified by the TBM manufacturer prior to the start up of the machine.
11.3.4 The Contractor shall provide, during the TBM assembly and the first 200m of
excavation for each TBM, a team of three specialists for each working shift from
the TBM / backup equipment Supplier(s). These three specialists shall be
experienced in TBM shield operation (1 person), electrical (including
Programmable Logic Controller (PLC)) (1 person) and mechanical/hydraulic (1
person) systems for the TBM / backup equipment. These specialists shall provide
technical assistance and training to all tunnelling and supervisory staff. The three
specialists shall be present onsite throughout the above work and additional
specialists shall be provided on a shift basis as necessary. The Contractor shall
submit the CVs (endorsed by the machine Supplier) of all TBM specialists to the
Engineer for acceptance 60 days before TBM start-up operations.
11.3.5 A technical representative from the machine manufacturer knowledgeable in the,
operation and maintenance of the TBM shall remain on site with the Contractors
staff at the construction site for the whole duration of the tunnelling works. This
person shall attend any meeting related to the TBM, the associated equipment
and its performance.
11.3.6 During the tunnelling operation, the Contractor shall provide and maintain CCTV
(closed circuit television) systems with at least three (3) cameras placed
strategically within each tunnel drive at ring build, shaft bottom and muck pit area
or at other locations indicated by the Engineer. Each CCTV system shall be
linked to colour monitors sited in the Engineers office and the cameras shall
move forward with the TBM.
11.3.7 STP operators and the Contractors chief mechanic(s) shall be trained and
certified by the STP manufacturer prior to the start of tunnelling. A technical
representative from the STP manufacturer competent in the assembly, operation,
maintenance and repair of the STP shall form part of Contractors staff at the
construction site for the whole duration of the tunnelling works.
MNW/TBM /25

11.3.8 For a period of three (3) months prior to tunnelling, through to completion of
tunnelling, the Contractor is to retain the services of a mud engineer or
consultant for the purposes of designing and where necessary modifying the Key
Performance Indicators (KPI) for the active slurry in all ground conditions. This
person is to have a minimum of 5 years relevant experience and be acceptable to
the Engineer. The mud engineer is to be available to attend meetings with the
Engineers staff on site as required.
11.3.9 Three (3) months prior to the commencement of tunnelling the Contractor is to
provide the KPI for the active slurry in all foreseeable ground types and indicate
where on the alignment these KPIs are to be applied. These KPIs are to address
as a minimum, Density, Marsh Funnel Viscosity, Plastic Viscosity, Fluid Loss, PH
etc.
11.3.10 From these KPIs specific hold points are to be derived for the commencement of
excavation, suspension of excavation and commencement of manned
intervention. The mud engineer along with the Contractors QP(D) responsible
is to endorse these KPIs and hold points.
11.3.11 The performance of the KPIs themselves are to be monitored throughout the
project through the daily and regular site tunnel meetings If it is deemed
necessary the KPIs may be revised by the Contractor to the acceptance of the
Engineer.
11.4
Primary Grouting
11.4.1 The primary grouting system shall be able to provide continuous, complete
backfill grouting of the annulus between the concrete segments and excavated
surface when the TBM is operated in closed mode. The TBM shall continuously
grout the tail void, as the TBM advances, through the tail shield using pipes or
channels embedded within the tail shield. A redundant pipe shall be provided at
each location for use in the event that the first pipe becomes blocked. The
grouting system shall include a means for washing out grout residue between
each advance.
11.4.2 A method statement for the proposed grouting method and sequence should be
presented to the Engineer for approval before the commencement of tunnelling.
11.4.3 The Contractor shall ensure that grouting pressures do not result in ground heave
or overstress or distortion of lining or distortion or damage to gaskets or damage
to other structures.
11.4.4 The Contractor shall use a two-component grout system, which will be batched
on the surface and then pumped down to the TBM. A retarding admixture shall be
added to the grout at the batching plant and then an accelerating admixture
added and mixed at the point of injection through the tailskin grout ports.
MNW/TBM /26

11.4.5 The amount of grout used and the grouting pressure shall be recorded, and if the
quantity falls short of that required to fill the space, further investigation and
grouting shall be carried out.
11.5
Secondary Grouting
11.5.1 Secondary grouting is the regrouting of lining and shall be completed as soon as
practicable but within 14 days of the primary grouting or when the face has
advanced 50 m from the location of primary grouting whichever first occurs.
Secondary grouting shall be at a pressure consistent with filling all voids but shall
not exceed the design pressures.
11.5.2 Secondary grouting shall be undertaken in selected rings by means of carefully
removing grout plugs from the tunnel lining and drilling a hole, through a blow out
preventer, to the back of the existing grout and injecting grout to the design
pressure.
11.5.3 Upon completion of secondary grouting, threaded grout plugs shall be fully
tightened into the lining. The grout plug fitted with a hydrophilic O ring shall be
capable of withstanding full hydrostatic pressure.
11.5.4 Complete records shall be kept of all pressures and volumes of grout injected
during the secondary grouting and submitted to the Engineer on a weekly basis.
11.6
TBM Dismantling
11.6.1 On completion of the drive, the machine shall be dismantled and removed from
the tunnel.
11.6.2 The machine design shall permit dismantling of the structure of the machine
within the shield skin, which may be left in place at the completion of the tunnel
drive, and then transported back along the tunnel to the launch shaft for removal.
Component dimensions should therefore be of a size compatible with such
process.
11.6.3 The Contractor shall submit a method statement explaining his proposals for the
dismantling and removing the TBM and back up gantries.
11.6.4 If the shield skin is abandoned on completion of the tunnel drive a segmental or
cast in-situ lining which complies fully with the requirements of the Specification
shall be constructed within the shield skin after removal of all mechanical parts.
MNW/TBM /27

12.
DOCUMENTATION
12.1
At Proposal Stage
12.1.1 The Contractor shall submit with his tender (in a proposal document), details of
the intended machine type, including specification and schematic drawings and
name not more than three preferred machine suppliers. These details should
include a description on his selection criteria with regard to soil and rock types
along the tunnel drives and their characteristics, control of ground movement /
settlement, groundwater pressures, calculations to demonstrate how TBM and its
associated plants will achieve the required advance rates for different types of
geology encountered, how interventions will be achieved and any other
considerations.
12.1.2 The Contractor shall submit details to demonstrate that his chosen TBM supplier
has the required experience, track record and capacity to design and fabricate
the TBMs to the Contractors programme.
12.1.3 The Contractor shall also supply with his tender a list of non-conformities,
identifying any aspect of his proposed TBM which fails to comply with the
requirements of this Specification, and provide a justification for such noncompliance.
12.1.4 In his submission, the Contractor shall provide evidence of two projects where
the Contractors proposed type of TBM has been used in similar ground
conditions as those likely to be encountered in the Works, detailed advance rates
achieved and ground settlements or settlement related incidents records.
12.2
After Award of Contract
12.2.1 As soon as possible after award of contract, the contractor shall confirm the TBM
manufacturer and shall make a joint presentation to the Engineer providing
details of the TBM design, layout and specification prior to fabrication.
12.2.2 The Contractor shall, within 2 months of the Commencement Date, provide the
Engineer with the following documentation:
i. Programme of manufacture, to include TBM design, procurement,
manufacture, inspection, factory testing, transport, site erection and
commissioning and initial trial excavation periods;
ii. Drawings and technical data (draft) of the TBM and all major equipment
groups;
iii. Spare parts listings, to include strategic items, estimated delivery times and
storage requirements;
iv. Emergency plans for gas incidents, fire incidents and water inundation;
MNW/TBM /28

v. Proposals demonstrating how the bearing will be changed from within the
tunnel;
vi. Proposed manning levels;
vii. TBM launch and dismantling proposals.
The Contractor shall provide details of the TBM design for the Engineers review
and acceptance. The manufacture of the TBM shall not commence until the
Engineer has approved the design. The approval of the Engineer does not relieve
the Contractor of any of his duties under the Contract.
12.2.3 Within three (3) months after the Contract award the Contractor shall provide
manufacturers specifications for each type and size of separation plant and a
draft STP operation manual which shall be specific to the plant proposed at site,
and design calculations for the slurry circulation system.
12.2.4 During the design stage of the TBM supply, the Contractor shall provide draft
method statements of how interventions will be achieved for the purposes of
cutter changing and cutterhead maintenance. Such Method Statements should
be finalised before commencement of tunnelling.
12.2.5 Three (3) months prior to commencement of tunnelling the Contractor is to submit
to the Engineer for acceptance his method statement for the maintenance and
refurbishment of all cutter tools. The method statement is to detail as a minimum
workshop requirements, cutter disc refurbishment procedure, cutter disc hub
wear limitations, limiting number of refurbishments for cutter disc hubs, cutter
types for varying ground, cutter tolerance for replacement / reuse. The method
statement is to be endorsed by the TBM supplier / cutter supplier.
12.2.6 The Contractor shall provide a scheme for preventive maintenance of the TBM
during its operation. The Contractor shall include a method statement detailing
the calibration and: replacement of pressure sensors to ensure that the face
pressure is accurately monitored throughout the tunnel drive.
12.2.7 Three (3) months prior to TBM launch, the Contractor shall provide a method
statement on how the TBM is to be launched. Details of launching frame, ground
treatment for the initial launch section, etc shall also be provided.
12.2.8 Within 14 days of completion of the TBM manufacturers factory testing and
commissioning, a copy of the manufacturers operating and maintenance
instructions for the TBM, written in English, shall be provided to the Engineer.
From the experiences gained during the factory demonstration of the changing of
the cutting tools the TBM manufacturer and Contractor should develop a safe
working procedure for the changing of the cutting tools for inclusion in the TBM
manual.
12.2.9 Prior to delivery to site of the STP, a copy of the manufacturers operating and
maintenance instructions for the Slurry Treatment plant, written in English, shall
be provided to the Engineer. This manual shall include details on the monitoring
and controlling of the slurry density, pH, rheology, sand content and viscosity to
ensure optimum face confinement, transportation and separation characteristics.
MNW/TBM /29

12.2.10 One week prior to the arrival at the port of Singapore of the TBM or any part of
it, the Contractor shall supply packing shipment lists in sufficient detail to allow
the Engineer to verify the arrival of all critical components including spares.
12.2.11 All the above documentation shall be considered by the Engineer without
prejudice to the Contractors responsibilities to provide a tunnelling system fit for
purpose. The Contractor shall remain solely responsible for the TBM fulfilling
the specified duties and requirements in a safe, secure and timely manner.
12.3
Manufacturing Progress Report
12.3.1 A report stating progress of the design and fabrication with respect to the
accepted programme, outlining any notable issues or occurrences, shall be
submitted to the Engineer on a monthly basis. Progress photos demonstrating
procurement of materials and fabrication shall be submitted with the report.
Viewing of the progress by the Engineer shall be arranged monthly by live video
link. The live video shall be accessible from the site office as well as the client
office. These monthly progress reports shall be required notwithstanding any
arrangements made to visit the factory as referred to in Clause 10.1.2.
12.4
After Commencement of Tunnelling
12.4.1 Upon completion of the first 200m drive, the Contractor shall provide the
Engineer with detailed as-built drawings of the TBM complete with any updates
following modifications carried out during the 200 m commissioning period as
appropriate
12.4.2 The contractor shall also supply a copy of the signed final acceptance certificate
for the TBM issued by the Contractor to the TBM supplier.
MNW/TBM /30

01 Tunnel Boring Machine TBM Specifications

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PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

TUNNEL BORING MACHINE (TBM) SPECIFICATIONS

CLOSED FACE MACHINES ...........................................................................................................3

PARTICULAR REQUIREMENTS FOR SLURRY MACHINES .....................................................10

PARTICULAR REQUIREMENTS FOR EPB MACHINES ............................................................16

ALIGNMENT CONTROL ...............................................................................................................18

MANUFACTURING & COMMISSIONING.....................................................................................23

TBM OPERATION & USE .............................................................................................................24

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

11.6 TBM Dismantling ....................................................................................................................27

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

Shield is defined as a tunnelling machine comprising a cylinder of metal that is

Semi mechanised tunnelling machine means a shield equipped with excavating

TBM (Tunnel Boring Machine) is a machine comprising excavating machinery

An open face TBM is defined as a shielded TBM where there is no pressure

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

TBM Selection Criteria

The Contractors proposed TBMs must be able to control ground movements,

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

Notwithstanding requirements stated elsewhere, it shall be entirely the

CLOSED FACE MACHINES

The TBMs shall be designed and manufactured in conformity with the

All closed face machines shall be designed to maintain pressure on the

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

Cutterhead and Cutters

The cutterhead shall be capable of bi-directional rotation, clockwise or

The TBM manufacturer is required to carry out a demonstration of the changing

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

Notwithstanding the requirement of clause 3.2.8, openings in the cutterhead shall

The cutterhead shall be driven by a variable speed electric or electro-hydraulic

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

Shield Body, Propulsion and Tailskin

A minimum of 6 pressure sensors shall be located on the pressure bulkhead (two

At each articulation joint there shall be a sufficient number of lubrication injection

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

incorporate automatic systems for monitoring, controlling and recording the

Compressed Air Provision

All airlocks shall conform to BS EN 12110:2002 or equivalent international

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

If the Contractor includes saturation diving techniques as one of his contingency

Probing and Ground Treatment

Ground stabilisation ahead of the TBM is considered an important tool in view of

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

PARTICULAR REQUIREMENTS FOR SLURRY MACHINES

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

Slurry Treatment Plant

268831MC/North-South Transmission Cable Tunnel Contract NS2

PART VIII - MATERIAL AND WORKMANSHIP SPECIFICATION

Flows into and through the separation plant (t/hr)