Dosco Introduction - Civils (NDCO)

An Introduction to the Dosco Civil Tunnelling Division
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An Introduction to Dosco
Contents Page
1 Dosco – a company profile 3

2 Dosco - worldwide 11
3 Introduction to Civil Tunnelling 12
4 Recent events at Dosco 16
5 Case History - Heathrow – Baggage Tunnel 20
6 Case History - Sewage Scheme development 25
7 Case History - Heathrow Paddington Express development 28
8 Case History – West Runton sewage outfall tunnel 34
9 Dosco Roadheaders 39
10 Cross Passage Machine 41
11 Sample product data sheets 52
12 Contacts 59
YOUR PARTNER FOR ALL ROUND QUALITY AND RELIABILITY

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1. Dosco – a company profile
History
Dosco Overseas Engineering Limited is UK based and since 1995 a member of the Amco
Corporation plc group. Located in Tuxford, Nottinghamshire, the company was founded in
the early 1950's by the Dominion Steel and Coal Company of Canada to market the Dosco
Miner in the UK coal mining industry.
Situated in North Nottinghamshire, Dosco is ideally

placed to serve the UK coal mining industry, and the
company's early successes were linked to the
mechanisation of that industry, which called for the
rapid development of gate roads for longwall faces.
As well as traditional boom type Roadheaders used
for development, Dosco has introduced machines
for use in high volume production of a range of
minerals.
In addition, machines for civil construction,

materials handling and mineral processing
form a key part of the product range.
From its inception, the company has pursued a policy of using specialist sub-contract
companies to manufacture Dosco designed parts, with final assembly and testing being
undertaken at the Tuxford site.
Design & manufacture
The Engineering Department employs a strong team of
qualified designers and support staff using the very latest
computer aided design and drafting equipment, including
three-dimensional solid modelling. Each new machine
design is in the hands of an experienced Project Manager,
backed by a pool of qualified design and detail staff.
Similarly, the Purchasing Department employ buyers
responsible for the purchase of proprietary items and the
outside manufacture of Dosco designed components. High
standards are demanded from suppliers, and professionally

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trained staff ensures that, while negotiating the keenest prices, quality and delivery are to the
required standards.
The production areas include machine

assembly, component sub-assembly,
fabrication, machining, and refurbishing
bays. Each machine is built at one assembly
point by a team of highly experienced,
specialist engineers, who then have an
interest in a particular machine for a
particular customer.
The company maintains a test area including

level working areas of soft and hard ground.
The areas are used for traction and loading trials, along with any ancillary testing of equipment.
Part of the site is used for cutting trials to assess machines in simulated conditions. During test,
data on hydraulic flow and pressure, electrical power, force, strain, temperature, noise and
vibration levels is measured and analysed.
Quality
Dosco is an ISO9001 registered company, and as such maintains an
independent Quality Assurance Department, responsible for
inspection of goods inwards, both Dosco design and proprietary parts.
The department also inspects component manufacture on suppliers'
premises. As well as component inspection, the department carries
out a final machine inspection to ensure the quality of the product and
traceability of all components.
Dosco received accredited certification to IS014001 in 2002. This

demonstrates Dosco’s commitment to improving their environmental
and conservation performance by minimising waste, controlling
pollution and protecting the industry's natural resources.
Spares back up
To maintain the company's reputation for keen

deliveries and ready availability of spares, the
Stores stock over £3m of component parts. A
24 hour spares supply and delivery service
operates within the UK, and consignment
stocks are placed with selected customers.
Stocks are maintained overseas in areas where

considerable numbers of machines are held,
with an Export Packing Department
despatching parts to customers world-wide.

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Sales support
Dosco's Sales and Service teams enhance the

company's reputation. A pre-sales service gives
advice on cutability, cutting head design and
performance estimates. The sales team are able to
discuss in depth the problems which prospective
customers may face, and to recommend equipment
for the project. The knowledge gained from a whole
range of applications over a long time period is
freely available.
Service engineers operate regionally within UK,

providing a comprehensive 24 hour cover. All are
experienced machine operators as well as fault
finders and trained maintenance men. Many have
experience of installing machines and training
operators and engineering staff in several regions of the world. The depth of knowledge allows
training of customers personnel either on site or at the Tuxford UK base.
Mineral Mining
In mineral mining, Dosco equipment has successfully

operated in some 52 countries world-wide, including almost
all the major coal producing countries. In addition to coal
mining, experience has been gained in many other minerals
including salt, potash, gypsum, iron ore, bauxite, and
phosphates. The range of machines, from the Dintheader at 17
tonnes to the TTM100 at 150 tonnes, enables Mining
Engineers to consider a Dosco machine for any mining
application.

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Civil Tunnelling
The rock cutting capability of Dosco equipment was quickly recognised by the construction
industry as an alternative to drill and blast in tunnelling operations, and a range of machines has
been developed for this purpose, including boom in shields and full face tunnel boring
machines for soft to medium ground.
Dosco has built an enviable reputation in the civil construction industry, providing machines for
rail and metro links in major cities around the UK, including Liverpool and Newcastle as well
as the underground link to Heathrow Airport's Terminal Four.
Following these earlier successes in the field,
Dosco extended its capability to the extent not
only of supplying the cutting element but the
complete tunnelling system including shield,
conveyor, segment transport and segment erector.
Dosco have supplied large shield machines to

prestigious projects such as the Heathrow to
Paddington Express Line and the extension to the
Jubilee underground in London. A current project
is a 6.84m diameter back-hoe in shield machine
which is now being used on the development of the Channel Tunnel Rail Link (CTRL) under
London, UK.
Not only boom in shield machines, but also full

face tunnel boring machines (TBM's) have
become part of the company's product range. A
typical machine supplied for a sewage outfall
tunnel under the North Sea was designed to be
used in open mode with a full length belt
conveyor, or in closed mode with a screw
conveyor operating through a bulkhead for soft
ground sections.

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Materials Handling & Mineral Processing
In the Materials Handling field, Dosco has a manufacturing and sales agreement with
Bridgestone of Japan for the unique pipe conveyor.
Pipe conveyors transport materials in a totally

enclosed environment (eliminating any
spillage and contamination of the surrounding
area) they are ideal where wastage and/or
environmental issues are of major importance.
The system design allows negotiation of steep

gradients (30 degrees or more) and sharp
curves. The conveyor can be curved both
horizontally and vertically - allowing it to
follow land/site contours.
The wide range of belt materials includes food quality grade. Conveyor diameters range from
150mm to 850mm diameters. This gives volume flows of 95m3/hr up to 7,300m3/hr
respectively.
Dosco has developed a range of crushers for

the mining, quarrying and construction
industries.
Dosco manufacture high torque, slow speed,

twin roll crushers, incorporating picks or cast
manganese teeth. The innovative tooth design
allows for rapid teeth changes, minimising
downtime.
The range can process from 100 - 5000 tph

with installed powers of 100 kW – 500 kW.
Suitable for materials up to 280 MPa compressive strength.

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A recent addition to the Materials Handling product

range is a range of heavy duty “front end” shredders
which reduce waste volume to a manageable size.
The shredders are ideal for sheet metals, wood,

plastics, some construction and demolition waste,
household waste and rubber. They have solid hooked
cutting discs or alternatively cast teeth for easy
replacement.
Special Engineering Products
Special Engineering Projects form a key part of the Dosco product range. The specification of
work that can be done seems endless. Just some of projects to date range from sub sea vehicles
for diamond mining through to a tuyere cutter for cleaning out smelting furnaces. Projects of all
sizes are carried out. Dosco offers a range of services from feasibility studies, design,
installation and commissioning right through to full turnkey supply.

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World-wide support
Dosco's ability to satisfy world demand is based on the early recognition of the importance of
sound engineering, reliable after-sales service, and a constant presence in the field.
To this end, the company has established a world-wide network of distributors and agents. As
part of the drive for market penetration in certain world markets, licence agreements have been
signed allowing indigenous manufacture of Dosco products, in India and in Poland.
To support needs of the coal mines in the Kuzbass region of Russia, a

Dosco representative office has been opened in Kemerovo, Russia.
The Dosco facility (which has been operational since March 2003 offers
local support, technical advice, spares back up and after sales service,
predominantly to the coal mining industry.
To offer the best possible support Russian approvals have been obtained for four key models of
Dosco Roadheaders.
• Mk2B
• MD1100
• LH1300
• MK3
The Dosco stand at the Ugol Rossi Mining

Exhibition, Novokuznetsk, Russia, June 2003
As part of the support to new developments in Iran, a

representative office was opened in Tehran on 10th June 2003.
The local support includes: Technical advice, on-site support,

Maintenance back up, Spares holding facility and Engineering
workshop facility.
Iranian based engineers trained by Dosco personnel will be available for on site support.
Experienced Dosco Service Engineers are also able to offer back up on site, including
commissioning, training and machine maintenance.

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New workshop facility
As part of the continued expansion

programme for Dosco an additional
workshop has been built at the companies
Tuxford location.
Primarily for large machines the workshop

which is 40m long, 25m wide and 15m high.
The first machine which has been built in

the new facilities is a civil tunnelling
machine for a project on the Piccadilly
Express Rail Link Extension, London, UK.
The new workshop during construction
The machine was delivered in October 2003.
The second machine to be built in the new facilities is another civil tunnelling machine, this
time for a project on the Heathrow High Speed Rail Link Extension, London, UK. The machine
is due for delivery January 2004.
Looking at the future
To date, Dosco has manufactured almost 3,000 machines and recognises that machinery
working under constant production pressures requires a constant commitment from the
manufacturer. That is exactly what Dosco aims to provide. By consultation, collaboration,
innovation, excellent engineering and service, Dosco continues to break new ground and
production records.

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2. Dosco – worldwide
The table below shows the countries where Dosco machines have been supplied:
Qty Country Qty Country

5 Argentina 1 Libya
20 Australia 5 Mexico
8 Belgium 1 Morocco
3 Brazil 1 Namibia
69 Canada 8 New Zealand
61 China 2 Nigeria
1 Chile 1 Northern Ireland
7 Czech Republic 13 Poland
1 Dubai 11 Romania
5 Egypt 3 Russia
1 Eire 6 Saudi Arabia
7 France 1 Slovak republic
12 Germany 6 South Africa
4 Hungary 18 Spain
58 India 6 Switzerland
4 Indonesia 1 Turkey
5 Italy 1 U.A.E
7 Japan 59 U.S.A
1 Kenya 2 Venezuela
4 Korea south 2 Yugoslavia
Machines supplied to the United Kingdom = 2395
Machines supplied to the rest of the world = 428

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3. Introduction to Civil Tunnelling

Dosco design, manufacture and refurbish tunnel boring machines (TBM's), semi mechanised
shields, Roadheaders and tunnelling systems for most types of strata. Complete tunnelling
systems are designed and manufactured incorporating cutting element, shield, conveyor,
segment transport and segment erector.
All equipment is designed and manufactured to meet exacting customer specifications.
Machine options for Civil Tunnelling applications include:
Shields with hydraulic or electrical cutting booms to cope with soft to medium rock
conditions.
Shields fitted with manual digging stations and/or back hoe combinations for use in soft
ground conditions
Full face EPB machines for unstable natural ground
Pipe jacking machines with a variety of cutter options
Full face TBM’s for hard and soft ground
Multidrill – percussive for straight line percussive drilling of small bore pipelines
Special purpose tracked machines
Shaft sinking machines
Roadheaders with a variety of boom options
Complete back up system
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The list below shows a selection of the applications where Dosco Civil Tunnelling machines
have been utilised:
Customer or location Equipment Application Qty

Balfour Beatty Backhoe Shield Rail 1
Balfour Beatty Backhoe Shield Rail 1
Taywood/Costain Backhoe Shield Metro 1
Amco Boom/Shield Sewer 1
Bradford Boom/Shield Sewer 1
Citra Australia Boom/Shield Sewer 1
Citra Australia Boom/Shield Sewer 1
Liverpool M E P A S. Boom/Shield Sewer 1
Manchester Boom/Shield Sewer 1
Miller Boom/Shield Transport 1
Miller Boom/Shield Sewer 1
Newcastle on Tyne Boom/Shield Metro 3
Paris, France Boom/Shield Water 1
Redcar Boom/Shield Water 2
Scotland Glasgow Boom/Shield Sewer 1
Stoke on Trent Boom/Shield Sewer 1
Bradford Boom/Shield Sewer 1
Bristol Boom/Shield Sewer 1
British Coal Boom/Shield Mine 1
Czech Republic Boom/Shield Metro 1
Grays Boom/Shield Water 1
Heathrow Express Boom/Shield Rail 1
Heysham Boom/Shield Water 1
London Boom/Shield Metro 3
Manchester Boom/Shield Sewer 1
Mansfield Kier Boom/Shield Sewer 1
Mansfield Kier Boom/Shield Sewer 1
McAlpine Boom/Shield Sewer 1
Midsomer Norton Boom/Shield Sewer 1
Palermo Sicily Boom/Shield Water 1
Palermo Sicily Boom/Shield Water 1
Ramsgate Boom/Shield Sewer 1
Rochester Boom/Shield Waste 1

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Selby Boom/Shield Mine 2
Sheffield (Don Valley) Boom/Shield Sewer 1
Sheffield (Don Valley) Boom/Shield Sewer 1
Switzerland Boom/Shield Road 4
Taywood/C Boom/Shield Metro 1
Wavertree Park, Liverpool Boom/Shield Sewer 1
Arabian Tunnels Saudi Arabia Continuous miner Road 1
EPB Conversion Thurrock E.P.B.M. Sewer 1
A E Yates Micro bore Gas 1
Rees Hough Micro bore Sewer 1
Balfour Beatty NATM Rail 1
Alnniraibid Saudi Arabia Roadheader Road 2
Alnniraibid Saudi Arabia Roadheader Road 1
Andre Borie France Roadheader Sewer 1
Australia Roadheader Sewer 2
Auxini Spain Roadheader Water 1
Balfour Beatty Roadheader Rail 1
Balfour Beatty Roadheader Rail 1
Barking UK Roadheader Water 1
Bristol Roadheader Sewer 1
Bristol Roadheader Water 2
Bristol Roadheader Sewer 1
Corean Spain Roadheader Water 1
Downers New Zealand Roadheader Road 2
Dumez France Roadheader Sewer 1
Italy Roadheader Water 1
Libya Roadheader Sewer 1
Liverpool link line Roadheader Rail 2
Liverpool loop line Roadheader Rail 3
New Zealand Roadheader Water 1
Ocisa Spain Roadheader Water 1
Ocisa Spain Roadheader Water 1
Rainbow MALTA Roadheader Trench 1
Turkey Roadheader Water 2
USA Roadheader Sewer 1
U S A Harlan tunnels Roadheader Road 1
Venezuela Roadheader Water 2
W I P P. U S A. Roadheader Waste 1
Korea Seoul Metro Roadheader Metro 2

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Saltash Plymouth Roadheader Road 1
Tarnco Saudi Arabia Roadheader Road 1
Dutco-Brochier Shaft Sinker Sewer 1
McAlpine Cromer T.B.M. Sewer 1
TBM Conversion - Dufermline T.B.M. Sewer 1
TBM Conversion - London T.B.M. Drain 1
TBM Conversion Dundee (HR) T.B.M. Sewer 1
TBM Conversion London T.B.M. Cable tunnel 2
TBM Conversion Thurrock T.B.M. Sewer 1

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4. Recent events at Dosco
Pipe Conveyor in Cement application
Dosco have designed and supplied two off pipe conveyors for handling cement at the RMC
owned Chelm Cement Plant located in Chelm, Poland.
The pipe conveyors are both 300m diameter and 200m long. They are part of a dual system
each carrying up to 325 tonnes/hour of cement, 14 hours per day.
The new pipe conveyors, which are part of an investment to improve and upgrade the plant
were erected by Polish main contractors EZO. Other mechanical parts were procured in Poland
by Dosco’s Polish office. The design work was carried out in the UK at Dosco’s head office in
Tuxford. Sourcing products locally in Poland enabled Dosco’s UK skills and engineering
expertise to be combined with the economies of local manufacture.
The pipe conveyor system has replaced an old conventional troughed belt conveyor. It has
already proved to be an efficient and cleaner system with lower maintenance costs.
Pipe conveyor handles woodchips
Dosco have recently designed, supplied and

commissioned a twin pipe conveyor handling
woodchips at a paper plant in the Czech
Republic. Main site contractor for the project
was FMW, Austria for the end client
Frantschach Pulp and Paper’s STETI plant in
the Czech Republic.
The pipe conveyors are both 350mm diameter.

Conveyor lengths are 376m and 547m. Both are
capable of transporting woodchips at a rate of 250 tonnes/hour (720m3/hr).
The system incorporates variable speed drives to adjust the conveyors’ fill rate and velocity and
is automatically controlled by a belt weigher on the incoming conventional feed belts. The set
up gives optimum efficiency and operational savings.
The layout includes curves and inclines – both vertical and horizontally, which negotiates a
complex route through the site at Steti. Many structural supports and mountings from existing
plant were utilised. The conveyors discharge at heights of 38m (line 1) and 50m (line 2).
As main contractor, FMW procured the steelwork locally and erected the system utilising the
Dosco designs and specifications. From receipt of order the equipment was designed,
manufactured, installed and commissioned by Dosco Engineers within 6 months.

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Roadheaders for Iran
Dosco Overseas Engineering Ltd, an Amco

Corporation Plc group company, has been
awarded a contract to supply four new
Roadheaders for use in the development of a
major new coal mine at Tabas in IRAN.
Dosco won the contract against strong

overseas competition. Deciding factors in the
selection of the Dosco MD1100 Roadheader
included its versatility, ability to work in
difficult ground conditions and the machines
impressive reliability record in the field. The Dosco machines for Iran during manufacture
Dosco’s ability to offer a rapid supply of the
machines was also a major factor.
Tabas mine located in the Parvadeh coalfield in the north eastern part of IRAN, will be the first
fully mechanised underground mine in the country. The new mine is scheduled to produce
750,000 tonnes of saleable coking coal each year. The coal will be used by the mines owners
and operators the National Iranian Steel Corporation (NISCO), to feed its steel making
operations at Esfehan. Throughout the project Dosco will be working closely with Cementation
Skanska who are the contractor responsible for providing specialist mining services for main
contractor IRITEC/IRASCO.
The contract is being supplied in three stages.

The first machine was completed mid June
2003, the second machine in mid July 2003
and the third and fourth machines by end July
2003.
Dosco MD1100 Roadheader

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Dosco twin roll crusher for Spanish quarry
Dosco has supplied a twin roll crusher to be utilised

in a Spanish quarry. The crusher is acting in a
secondary stage. It will process a special mineral mix
of clay, shale and sandstone from a nominal infeed of
- 300 mm to give a nominal product size of 50 mm.
Throughput is 1200 t/h.
The crusher has been purchased by ERAL, Equipos y

Procesos, S. A. of Madrid for installation at a WBB
quarry located in Castellón in East Spain. The quarry
is a 3.5 million tonnes per year facility serving the
Dosco crusher during manufacture
Spanish ceramic industry.
The Dosco model DTR825 twin roll crusher incorporates

cast manganese cutting teeth. The innovative way in which
the teeth are retained allows for rapid change in situ without
the need to remove the rolls.
The crusher has a throat size of 2m width x 2.5 m long.

Each roll is individually powered by a 200 kW motor via a
Renold fluid coupling and a David Brown “G series” triple
reduction gearbox.
Dosco crusher during installation
The crusher is to be commissioned during July2003.
Dosco machine for Channel Tunnel Rail Link (CTRL)
A 6.84m diameter open-shield backhoe has been

designed and manufactured by Dosco for use on the
£107 million, Contract 103 of the Channel Tunnel
Chris Henderson. www.chp-

Rail Link Development.
The machine is being operated by a Kier

Construction Ltd/ Edmund Nuttall Ltd joint venture
photo com
(KNJV).
A local competition organised by KNJV was held

in local London schools to suggest a name for the
new machine. The name selected from the hundreds
of entries was “Getrude”.
Weighing in excess of 250 tonnes and over 50m long Gertrude was taken in sections from
Tuxford to her launch site in London. Gertrude starts her underground journey from King Cross
Station in August 2003, and will excavate the 650m twin-tube tunnels as part of the Thameslink
2000 project.

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Roadheaders with on-board bolting for UK Coal
The on-board bolting system for Roadheaders was designed by Dosco in conjunction with UK
Coal Mining Ltd and the bolter manufacturers, Hydramatic Engineering Ltd.
There are many benefits with on-board hydraulic

bolting systems as opposed to the traditional hand
held systems.
• Hydraulic bolters give a fast bolt up time and a

consistent high torque to the bolts. This
provides improved consistency in the standard
of bolting and hence improved strata control.
• Reduced operator fatigue as the operation is
much less physically demanding and very
importantly retains the skills of the operators,
who are restricted in the use of hand held A Dosco MD1100 Roadheader undergoing
machines due to hand/arm vibration. modification during June 2003 for UK Coal
The clever design enables the rigs and mounts to fold out of the way during cutting operations.
They are then powered forwards hydraulically for the bolting operation.
UK Coal now has a fleet of Dosco Roadheading machines with on-board roof and rib bolters
fitted. Other machines have been modified to enable on-board bolters to be fitted underground
at a later date if required.

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5. Case History - Heathrow Airport Baggage Tunnel

The Heathrow Baggage Tunnel project was the
first outing for the machine featured in Section 5
of this document.
The project was to drive a 4.6m diameter, 1.2 km

long tunnel designed to house a high-tech
conveyor system to move baggage from Terminal
1 to Terminal 4. The tunnel route took it under all
the main runways away from the air traffic above.
The strata was typical London clay. In the

unweathered state it is stiff to very stiff, grey Dosco model TM1800S boom in-shield
fissured clay containing silt lenses. Sand and tunnelling machine
gravel may also be present. Relatively thin
calcareous claystone bands occur throughout the sequence, in addition to hard cemented
calcareous concentrations known as separation nodules.
Project details

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The tunnel was worked from a shaft sunk on an island between taxiways in the middle of the
airport apron.
The machine was guided manually using laser sight marks.
Throughout the project steady progress of 16m/day was maintained through the very consistent
clay.
The tunnel was approximately 25m below the runway level. Settlement to the runways and
taxiways had to be kept below 20mm. Even more sensitive was the Piccadilly line, where the
bore passed just 4m below the London Underground Tunnel.
By keeping the boring shield moving continuously day and night, plus some very skilful work
at the head, surface movement figures of around 10mm to 15mm were returned, which were
well inside permitted tolerances.
The tunnel was noted throughout its progress for its extreme cleanliness, much of which was
attributed to the efficient muck away process.
Machine information
Boom
A Dosco model TM1800S boom was utilised This comprised a 65kW electrically driven boom
cutter mounted onto a pedestal frame. The mounting allows the boom to arc and lift sufficiently
to cover the whole tunnel face. The pedestal was mounted onto a slew ring bearing, which is
mounted on a sliding bracket. This enables the boom to move longitudinally in/out from the
tunnel face sufficiently to excavate a minimum of one ring depth forwards of the shield cutting
edge.
All boom functions were controlled by manual lever valves. Additionally all functions were
fully protected against hose burst, system failure and intensification.
Shield
Housed in the shield were 14 off 180mm bore x 1600mm stroke shove rams. Each shove ram
could be individually selected for either shove or retract.
Erector
A heavy duty 3600 ring erector with vacuum pads was utilised. A heavy duty slide enabled the
accurate positioning of the erector.
Details of the tunnel lining are shown on page 22.
Back up

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The back up system comprised 2 sledges.
The first provided space for the hydraulic power pack and carried the feed magazine.
The second provided space for two segment bodies, segment off loading hoist (electric) on a
runway beam, 0.7m wide conveyor and space for shuttle car.
A closed water cooling package was incorporated into the backup system.
Tunnel lining

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Machine Specification
Shield
Shield o/d 4800 mm
Shield length 3625 mm
Face rams 4 x 180 mm bore 1400 mm stroke
Shove rams 16 off
Capacity @ 345 kg/cm2 861 kN
Stroke 1200 mm
Total thrust (all rams) 13776 kN
TM1800S boom
Cutting head motor 65 kW
Lifting rams 2 No
Lifting Force 32 kN
Arcing rams 2 No
Arcing force 33 kN
Sumping ram 1 No
Sumping ram force 119 kN
Conveyor
Conveyor Troughed rubber belt
Drive Hydraulic
Rating 10 kW
Speed 1 m/s
Hydraulic power pack

Shove pump 1 No
Capacity @ 345kg/cm2 64 l/min
Conveyor pump 1 No
Capacity @ 210 kg/cm2 32 l/min
TM1800S pump 1 No
Capacity @ 210 kg/cm2 124 l/min

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Electric's
Shove, erector, magazine & conveyor pump 75 kW
TM1800S pump 55 kW
TM1800S cutter motor 65 kW
Lighting 8 kW
Spare capacity 26 kW
Total 229 kW
Installed power 300 kW

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6. Case History - Sewerage scheme development

During 1999 Morgan Tunnelling (formerly
Miller Tunnelling) were awarded the
contract to construct a tunnel for a sewage
treatment plant. This was to be constructed
in a disused quarry situated on the outskirts
of the town of Brixham, which is within the
Torbay district in the southwest of Great
Britain.
Southwest Water Authority had previously

been discharging untreated sewage into the
sea from around the Torbay area. It was
decided that all sewage should in future be Dosco model SB400 tunnelling machine used
for the application
treated before discharge into the sea. The
raw sewage was to be diverted to the new
treatment plant and then discharged to sea after treatment.
The project was to enable the untreated sewage to be pumped from existing sewer pipes
through a new connecting tunnel and into the new treatment plant.
Tunnel information
Tunnel diameter was 4.8m with a length of 475m, lined with concrete segments and pea gravel
to be injected for primary fill prior to grout injection. Substantial flows of water were expected
throughout (this reached 70 litres per second during tunnelling).
The strata was predominately fissured limestone which contained some sandstone and clay
deposits.
A 50m deep shaft was sunk in the corner of the quarry from where the machine was launched.
The machine was launched from the bottom of the shaft which was 7m diameter at the top
opening out to 10m diameter at the base.
A short back shunt was excavated to enable efficient launch and to facilitate pit bottom
equipment when muck loading.
Machine overview
Morgan Tunnelling had retained the Dosco tunnelling machine that they had used for the
“Baggage Tunnel” excavation under Heathrow International Airport in 1994 (full details are
given in Section 3).
After consultation with Dosco it was identified as suitable, with conversion, to carry out the
new project.

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The original machine incorporated a Dosco TM1800 type cutting boom. As the new application
involved cutting through harder strata it was decided the boom should be converted to a SB400
type.
The work required involved a major reconfiguration of the cutting boom. The original boom
was mounted in the invert, whereas the new SB400 boom was a top mounted slide unit. A key
advantage of the reconfiguration was that it allowed for greater capacity for loading muck and
gave much greater access within the shield.
Dosco proposed the use of their profile guidance system, which would ensure that overcuts
were controlled by the driver thereby controlling the amount of pea gravel/grout used. The
system also ensures that the driver has complete knowledge of the position of the boom
especially whilst it is buried in the invert muck pile.
It was decided that during the rebuild process a secondary provision should be designed for the
drilling of ground found to be harder than the boom capability.
Dosco’s solution was to store a drill upon the top of the

scraper conveyor. To utilise the drill two special brackets
were fixed to the boom. The drill could then be moved
down the conveyor and picked up onto the cutting head
of the boom. By engaging hydraulic drive mode (instead
of the normal electric drive) the drill could be
manoeuvred into any position around the tunnel face for
a suitable drill and blast pattern.
The machine utilised a single type SB400 boom powered

by a 142 kW, water-cooled electric motor.
The boom was hydraulically operated from a single

joystick control mounted in front of the operator. The
boom could be raised, lowered and arced from side to
side and the whole assembly traversed forward and
backward on the pedestal support (sledge) slides.
Drill unit shown mounted on boom
The shield progressed forward using sixteen equally spaced cylinders pushing off the last ring
erected. The rings were made up from a number of segments put in place using a rotary vacuum
segment erector located in the rear of the shield.

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As the machine moved forward it towed four sledges.
• Sledge number 1 housed the hydraulic power

pack, electric control panels, transformer and
scraper conveyor.
• Sledge number 2 provided space for the
segment flat cars and a hoist to lift and transport
the segments to the segment feeder.
• Sledges number 3 and 4 provided space for the
segment and muck wagons as well as support
for the belt conveyor and ventilation ducting
and cassette. A full Fire Fighting System was
incorporated within the Back-Up System. Machine back up system
Machine Specification
SB400U boom
Cutting head motor 142 kW
Cutting head speed 27 or 50 rpm
Lifting rams 2 No
Lifting Force 110 kN
Lifting ram stroke 370 mm
Arcing rams 2 No
Arcing force 130 kN
Arcing ram stroke 330 mm
Sumping ram 1 No
Sumping ram force 234 kN
Sumping ram stroke 750 mm
Electric's
Existing power pack motor 90 kW D.O.L
SB400U Boom 142 kW D.O.L
Hoist 7 kW D.O.L
Lighting 8 kW D.O.L
Conveyor 11 kW D.O.L
Vacuum Pump 1.1 kW D.O.L
Total installed power 259.1 kW
Transformer rating 300 kVA

27
7. Case History - Heathrow Paddington Express development

The Heathrow Express is a high-speed rail link offering the fastest journey time between
Heathrow Airport and Paddington - just 16 minutes. Its success has already resulted in the
strengthening of the train sets. The project was to drive a 6.1m diameter, 7.5 km long tunnel
and the development of two new underground stations, one serving Terminals 1, 2 and 3, and a
second, four miles away, serving Terminal 4.
For the first 18 km, the route follows the Great Western Main line to Airport Junction, near
Hayes. Here, Heathrow Express trains leave the main line to enter the tunnel that sweeps
underneath the heart of the airport.
The strata was typical London clay.

28
Machine information – main tunnel (6.1m outside diameter)
A Dosco model SB400 shield type tunnelling machine was designed for construction of the
7.5km tunnel and two identical “Station shields” for the new underground stations.
The model SB400 machine incorporated a

single boom powered by a 142kW, water-
cooled electric motor. The boom could be
raised, lowered, arced from side to side and
the whole boom assembly traversed forward
and rearward on the sledge unit slides.
A flipper arm – located under the boom

gathered debris and loaded it onto the belt
conveyor.
The shield pushed forward using seventeen

equally spaced cylinders pushing off the last Type SB400 tunnelling machine –
ring erected. The rings were made up from a used for main tunnel
number of segments put in place using a rotary segment erector located in the rear of the shield.
Tunnel lining

29
The machine back up comprised seven sledges.
• Sledge number 1 consisted of an upper and lower deck. Space for the hydraulic pumps is on
the lower level and hydraulic oil tank on the upper level. The segment feed magazine was
located under the lower deck level. Mounted centrally is a hydraulically indexed ladder. The
ladder carried a series of sprung loaded pawls which push each individual segment forward
through the magazine. The magazine was able to hold seven segments.
• Sledge number 2 housed the segment off-loading hoist and monorail, which enabled a
segment to be off-loaded from the segment bogie and placed in the segment feed magazine.
Space is provided for two segment and one grout bogie.
• Sledges number 3 to 7 provided space for the electrical control console, transformer and
isolator.
Space was provided for 5 off 14m3 muck skips. These ran on the wagon wheel flanges whilst
within the back up sledges. This facility allowed permanent rail to be laid loose inside the
sledges. The loose rail was connected to the permanent rail in the tunnel, so as the machine
advanced it pulled off the rear sledge, where sleepers were placed under it. This method gives
continual railing up, allowing for a much quicker machine advance.
The soil was removed from the shield by a belt conveyor, which was elevated 170 to the crown
of the tunnel. It then turned horizontal for 30m and then discharged into the muck skips.
Advance rates
Advances of up to 60m/day were recorded during the work. The efficient muck away system
was a significant contributor to this effectiveness.
Machine specification
Shield
Outer diameter 6115 mm
Overall length 7770 mm
Cutting edge thickness 60 mm
Diaphragm thickness 50 mm
Shove rams 19 No
Stroke 1400 mm
Capacity 87 tonnes
Total thrust @ 345 kg/cm2 1673 tonnes
Shove time – extend 8 minutes
- retract 3 minutes

30
SB400 boom
Cutting head speed 50 rpm
Cutting head power 142 kW
Lift rams 2 No
Lifting force 110 kN
Stroke 370 mm
Working pressure 140 kg/cm2
Sumping ram 1 No
Sumping force at cutting edge 234 kN
Stroke 750 mm
Cutting rate (average) 110 m3/hr
Erector
Type Rotary ring
Maximum rotation +- 2000
Speed of rotation (variable) 0-1 rpm
Ram capacity 26.4 kN
Stroke 400 mm
Number of pick-up head rams 1 No
Stroke 100 mm
Number of deflecting rams 2 No
Stroke 100 mm
Erector hydraulic system pressure 140 kg/m2
Segment magazine
Number of index rams 1 No
Ram capacity 253 kN
Stroke 1300 mm
Maximum working pressure 210 kg/cm2
Segment handling hoist

Type Electric
Capacity 29.4 kN
Hoist speed 3 & 10 m/min
Travel speed 15 m/min
Belt conveyor
Type 1000 mm wide troughed rubber belt
Type of drive Electric drum
Rating 20 kW
Capacity 350 tonnes/hour
Speed 1-10 m/sec

31
HYDRAULICS
Shield
Shield shove and face rams, and erector 1 No
Capacity 90 l/min
Electric motor rating 55 kW
Segment feed magazine

Index ram pump 1 No
Capacity 65 l/min
Boom
Arcing, lifting and sumping 1 No
Capacity 65 l/min
Electrics
Shield 55 kW
Boom 30 kW
Filler pump 190 kW
Hoist 3 kW
Lighting 7.3 kW
Belt conveyor 11 kW
Spare capacity:
1 @ 7.5 kW 7.5 kW
3 @ 10 kW 30 kW
Total installed power 342kW

Transformer 400 kVA

32
Underground stations
Two off 9.1m diameter shields were supplied and used in

the construction of lined tunnels 8.4m inside diameter.
The body of the shield consisted of 26 segments bolted
together. The body was then lined with steel plates bolted
to the segments to form a detachable steel body and
tailskin.
Station shield – 9.1m outside diameter
Material was excavated from the upper sections of the
tunnel by “hand dig” and in the lower section a slew type
back-hoe was used. The back hoe was also used to load the excavated material onto the
conveyor.
As the machine moved forward it towed three sledges behind it.
• Sledge number 1 – had two upper platform decks used for

grouting and bolting of the upper segments
• Sledges 2 and 3 – carried the rail track and loco wagons.
To facilitate on-site assembly the shield was split into

segments. These were then bolted and doweled together on
assembly.
The machine was designed to work at a maximum depth of

40m to the tunnel invert.
Completed tunnel
Both shields were designed and built in just 19 weeks from the go-ahead being given.

33
8. Case history – West Runton sewage outfall tunnel

The West Runton outfall tunnel was originally designed as a pulled pipe in a shallow trench on
the sea bed to be covered by 2m long “Taperweight” blocks and rock armour. The contractor
won the contract with an alternative bid to build a tunnel.
The project was to drive a 2.64m (104”) diameter, 2.2km tunnel out to sea through the
following strata:
• Chalk containing flints

• Pockets of silt/sand
The chalk was predominantly grade 5

(completely weathered without bedding or
jointing) and grade 4 (less weathered and is
friable and rubbly with some defined bedding
and jointing) with areas of grade 3 (pockets
of unweathered chalk within the weathered
zones).
The flints were found to be up to 700mm diameter (the forecast predicted 150mm diameter).
Most of the length of the tunnel was subject to hydrostatic pressure from the North Sea at a
minimum of 5.3m above the tunnel.
Schematic of tunnel
Sewer main 32m deep shaft 7.5m min cover between 2 x tunnel bore dia Skin of TBM
chalkhead and crown of between left in place
bore in tidal range chalkhead & crown
Sea Level of bore
2.64m OD
outfall tunnel
Machine information
A Dosco full face TBM with three cutter arms equipped with tungsten carbide tipped cutting
tools was supplied. The three openings were fitted with hydraulically operated flood inundation
doors for control or shut off of the excavated material. The shield body was articulated and
housed eight shove rams and a rotary segment erector.

34
The machine was designed to operate in two modes – EPB mode and open mode:
EPB mode – the cutter head chamber was sealed off from the main tunnel by a bolted-
on bulkhead adapter. A hydraulically driven screw conveyor passed through to the
cutting head chamber and controlled the rate of material discharge.
Open mode – by removing the screw conveyor and extending the belt conveyor into the
excavation chamber the TBM could operate in open non-pressurised mode. The cut soil
was lifted and discharged onto a 500mm wide belt conveyor, which discharged into
2.5m3 dirt wagons.
The segment erector was a rotary ring type, mounted off the shield rear diaphragm by six
wheels. The bolted trapezoidal precast concrete rings comprised six segments that were fitted
with a hydrophilic water sealing gasket.
Tunnel lining

35
Back up Equipment
The back up equipment comprised 5 No sledges:
Sledge No 1 provided space for the transformer and isolator (mounted above the segment feed
magazine). The segment feed magazine comprised a curved section which had mounted on it a
hydraulically indexed ladder.
Mounted on the ladder were a series of spring loaded pawls, these could push individual
segments forward, eventually cantilevering them into the tail skin building area.
Sledge No 2 provided apace for the segment bogies. The segments were off loaded by a special
hoist which transported them to the load point of the segment magazine.
Sledges 3 to 5 provided space for the 4 No 2.5 m3 muck wagons and supported the 500mm
wide belt conveyor.
The belt conveyor was specially designed so that the load end could be articulated enabling it to
fit into the cutter chamber when the machine was in EPB mode.
To convert the machine from open to EPB mode the conveyor was retracted and the angle
changed.
The screw conveyor was then installed.
Machine specification
Shield
Outer diameter 2642mm (104”)
Overall length 5125 mm
Articulation rams 8 No
Capacity 411 kN each
Stroke 125 mm
Shove rams 8 No
Stroke 1400 mm
Maximum advance rate – open mode 20cm min
Maximum advance rate – EPB mode 7 cm/min
Cutter head
Drive Hydraulic
Speed Varaiable 1.73 to 3.25 rpm
Torque 360 kN @ 3.25 rpm, 676 Kn @ 1.73 rpm

36
Inundation Door rams (2 No)

Stroke 450 mm
Screw conveyor
Type of drive Hydraulic
Rating 20 kW
Capacity 0 to 40.5 m3/hr
Speed Variable 0 – 29 rpm
Conveyor
Type 500 mm wide troughed belt
Speed Variable 0 to 1.5 m/s
Capacity 200 tonnes/hour
Erector
Type Rotary ring
Rortation drive Hydraulic braked motor
Speed of rotation Variable 0 to 2.5 rpm
Index Ram 1 No
Capacity 161 kN
Tilt Ram 2 No
Ram capacity 58 kN each
Longitudinal travel ram 1 No
Capacity 161 kN
Hydraulic power pack

Cutter head drive pump 1 No
Capacity 429 l/min @ 200 bar, 229 l/min @ 375 bar
Shove and articulation pump 1 No
Capacity @ 34.5 bar max 24.5 l/min
Minimum shove time using all rams 6.2 mins
Conveyor/erector pump 1 No
Capacity @ 210 bar max 74 l/min
Screw conveyor 1 No
Capacity @ 200 bar max Variable 0 – 56 l/min
Electrics
Cutter head pump 185 kW
Shove/articulation/conveyor/erector pump 45 kW
Screw conveyor 22.5 kW
Lighting 8 kW
Spare capacity 30kW
Total power 290.5 kW
Transformer capacity 350 kVA

37
Additional information
The machine was designed, manufactured and delivered within 14 weeks of the order being
placed.
The 45 tonnes TBM was lowered in one piece nose first down the 32m deep entry shaft.
The tunnel was driven on a maximum 1 in 90 downhill drive. It would have been preferred to
drive the tunnel on a level or slightly uphill, but this would have meant a launch shaft twice the
depth.

38
9. Dosco Roadheaders
Electrically or hydraulically operated cutting booms on Dosco Roadheaders are an efficient

tunnelling method for soft to medium ground (up to a nominal 140 MPa compressive strength).
The performance of the cutting boom is directly related to the ground conditions. Whilst
material hardness is a key factor in determining efficiency the composition of the material e.g.
whether the material has fractures or is massive, the strata mix of the face to be cut and the
surrounding strata conditions are all crucial factors.
Popular models of Dosco Roadheaders for Civil Tunnelling applications include the following:
Typical specification:
Model Power on cutting boom Machine weight

(nominal)
MD1100 From 82 kW (axial) 33 tonnes
From 112 kW (transverse)
Mk2b From 82 kW 44 tonnes
LH1300 Up to 225 kW 58 tonnes
Mk3 From 147 kW 85 tonnes
Typical model Mk2b Roadheader Typical model MD1100 Roadheader

39
Dosco Roadheaders can also be supplied complete with an on-board bolting facility, for both
roof and rib bolting. This rapidly speeds up developments using roof and rib bolts as the
method for tunnel lining.
The rigs and mounts have been cleverly designed so that they fold out of the way during cutting
operations. For the bolting operation they are then powered forwards hydraulically.
LH1400 Roadheaders complete with hydraulic on-board bolting equipment

40
10. Cross Passage Machine
A recently developed tracked machine, ideally suited for the economic construction of Cross
Passages to link together twin tunnels.
The Cross Passage Machine is highly manoeuvrable versatile. It incorporates a quick hitch
facility to allow use of a rotary backhoe, cutting head, bucket or hydraulic impact hammer.
A single operator can perform all machine functions. The operator can either work from a cab
on the machine or control it remotely.
Additional applications include production of underground sumps and stores.
Cross Passage Machine with Rotary Backhoe fitted Cross Passage Machine with cutting head fitted

41
11. Sample data sheets
The following pages show data sheets for just some of

the extensive Dosco product range. For more
information visit www.dosco.co.uk

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58
12. Contacts
Your local Dosco agent:
Mr Al Leeming (e-mail: al.leeming@ndcogroup.com or info@ndcogroup.com )
NDCO Construction Services Inc.

205, 3237 King George Hwy
Surrey, BC V4P 1B7
Canada
Tel: +1 604-535-7488 Fax: +1 604-535-7499
Key contacts at Dosco:
Mining Products
Mr Philip Adrych - Export Sales Engineer, email: padrych@dosco.co.uk

Mr David Parnham - UK Sales Manager, email: dparnham@dosco.co.uk
Materials Handling
Mr Paul Holt - Materials Handling Manager - Pipe Conveyors, email:

pholt@dosco.co.uk
Civil Tunnelling
Mr David Keward - Civils Sales Manager, email: dkeward@dosco.co.uk
Marketing
Mrs Jackie Rhodes – Marketing Manager, e-mail: jrhodes@dosco.co.uk
Directors
Mr Michael Waltham, e-mail: mwaltham@dosco.co.uk
Contact address
Dosco Overseas Engineering Ltd, Ollerton Road, Tuxford, Newark, Nottinghamshire, NG22 0PQ, UK
Tel: +44 (0)1777 870621 Fax: +44 (0)1777 871580

e-mail: info@dosco.co.uk Website : www.dosco.co.uk

59
Your local Dosco agent:
Mr Al Leeming
NDCO Group of Companies

205, 3237 King George Hwy
Surrey, BC V4P 1B7
Canada
Tel: + 1 604-535-7488
Fax: +1 604-535-7499
Email: al.leeming@ndcogroup.com
Dosco Overseas Engineering Ltd

Ollerton Road, Tuxford
Newark, Nottinghamshire
NG22 0PQ, UK
Tel: +44 (0)1777 870621

Fax: +44 (0)1777 871580
Web: www.dosco.co.uk Prepared: October 2003

e-mail: info@dosco.co.uk
60

Dosco Introduction - Civils (NDCO)

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An Introduction to the Dosco Civil Tunnelling Division

1 Dosco – a company profile 3

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1. Dosco – a company profile

Situated in North Nottinghamshire, Dosco is ideally

In addition, machines for civil construction,

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The production areas include machine

The company maintains a test area including

Dosco received accredited certification to IS014001 in 2002. This

To maintain the company's reputation for keen

Stocks are maintained overseas in areas where

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Dosco's Sales and Service teams enhance the

Service engineers operate regionally within UK,

In mineral mining, Dosco equipment has successfully

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Dosco have supplied large shield machines to

Not only boom in shield machines, but also full

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Materials Handling & Mineral Processing

Pipe conveyors transport materials in a totally

The system design allows negotiation of steep

Dosco has developed a range of crushers for

Dosco manufacture high torque, slow speed,

The range can process from 100 - 5000 tph

Suitable for materials up to 280 MPa compressive strength.

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A recent addition to the Materials Handling product

The shredders are ideal for sheet metals, wood,

Special Engineering Products

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To support needs of the coal mines in the Kuzbass region of Russia, a

The Dosco stand at the Ugol Rossi Mining

As part of the support to new developments in Iran, a

The local support includes: Technical advice, on-site support,

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New workshop facility

As part of the continued expansion

Primarily for large machines the workshop

The first machine which has been built in

Looking at the future

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Qty Country Qty Country

Machines supplied to the United Kingdom = 2395

Machines supplied to the rest of the world = 428

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3. Introduction to Civil Tunnelling

All equipment is designed and manufactured to meet exacting customer specifications.

Machine options for Civil Tunnelling applications include:

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Customer or location Equipment Application Qty

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Customer or location Equipment Application Qty

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Customer or location Equipment Application Qty

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4. Recent events at Dosco

Pipe Conveyor in Cement application

Pipe conveyor handles woodchips

Dosco have recently designed, supplied and

The pipe conveyors are both 350mm diameter.

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