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LAMANNA Luigi Franco
February, 2015
Introduction / Applications
TBM:
- Main bearing sealant (greases)
- Tail sealant
- Soil conditioning (EPB)
- Spray applied waterproofing membrane
- Injection
HARD ROCK TBM:
- Anti-wear and Anti-dust
- Anti-clogging
- Anchoring
- Spray applied waterproofing membrane
- Injection
“GLOBALSEAL-TBM/C-EC”
• INJECTION TAIL SEALANT IN THE BRUSHES WHEN TUNNELLING - HIGHLY RESISTANT
AGAINST WATER - ALLROUNDER - NOT MIXABLE WITH ANNULUS GROUT
(CONSUMPTION APPROXIMATELY: 0,6 – 1,5 kg/m²)
• GRASSO SIGILLANTE PER LE SPAZZOLE DI CODA
“GLOBALSEAL-TBM/T-EC”
• MAIN BEARING SEALING COMPOUND (BIODEGRADABLE, PLANT OIL BASED – with
MERKEL agreement)
• GRASSO SIGILLANTE PER LA GUARNIZIONE DEL CUSCINETTO DELLA TESTA
“GLOBALSEAL-TBM/C-1P”
• FIRST PACKING OF THE TAIL SEAL BRUSHES
• GRASSO SIGILLANTE DI PRIMO RIEMPIMENTO
MAIN BEARING GREASES and TAIL SEALANTS
THE NAME PRODUCTS, DESCRIPTION AND CHARACTERISTICS:
MAIN BEARING SEALING COMPOUND SEALING PRODUCT FOR CUTTING HEAD BEARING SEAL OF TUNNELLING MACHINE
GLOBALSEAL-TBM/T-EC
SEALING PRODUCT FOR CUTTING HEAD BEARING SEAL OF TUNNELLING MACHINE
TAIL SEAL COMPOUND FOR TUNNELLING MACHINE TAIL SEALS
GLOBALSEAL-TBM/C-EC
TAIL SEAL COMPOUND FOR TUNNELLING MACHINE TAIL SEALS
SEALANTS
GLOBALSEAL-TBM/T-EC GLOBALSEAL-TBM/C-EC
METAL PLATE – CONSUMPTION “GLOBALSEAL-TBM/C-EC”: APPROXIMATELY 10 KG PER LINEAR METRE OF BRUSHES
“GLOBALSEAL-TBM/T-EC”:
WILL BE USED ON ALL ROTATING
ELEMENTS IN TUNNELING MACHINERY LIKE
THE MAIN BEARING AND SCREWS.
ALSO ABSORBES PRESSURE GRADIENTS.
THE NAME PRODUCTS, DESCRIPTION AND CHARACTERISTICS:
SURFACE-ACTIVE AGENTS AND POLYMERS
“GLOBALCRYL-46”
- LIQUID POLYMER FOR SOIL CONDITIONING IN TBM
- FOR BENTONITE SLURRY MODIFICATION IN SLURRY SHIELD MACHINES IN CASE OF HIGH
SOIL POROSITY OR SALINE WATER CONDITIONS
“ GLOBALFOAM-HG”
- FOAMING AGENTS SPECIALLY DEVELOPED FOR LIQUIDIZING AND ENABLING WORKABILITY
OF THE EXCAVATED SURFACE IN TBM (IS USED FOR SANDY AND SILTY SOIL OR WHEN THE
SOIL HUMIDITY IS HIGH)
- REDUCE THE STICKINESS OF SOIL, MINIMISING CLOGGING RISK
“ GLOBALFOAM-AS”
- RANGE OF UNIQUE ANTI-WEAR AND DUST SUPPRESSION TECHNOLOGY FOR HARD ROCK
TBM OPERATING IN ABRASIVE GROUND.
“GLOBALSPERSE-1/45” - ANTI-CLAY POLYMER AGENT FOR EARTH PRESSURE TBM (EPB) AND HARD ROCK MACHINE
PREMISE Depending on site, the following problems may be encountered:
Lubrication and soil conditioning are being increasingly used to improve the performance of tunnelling, pipe
jacking, microtunnelling and horizontal directional drilling (HDD). The lubrication and conditioning may be
effected by the addition of suitable agents at various points throughout the tunnelling process, such as: at the
point of cut in the tunnel face; within the cutter head; in the muck removal system; around the outside of the
tunnelling shield and/or the pipes in a tunnel or pipe line formed by pipe jacking or microtunnelling; in the
separation units of a slurry system; or to muck on its way to tip. This improvement may come about in a number
of ways which are :
· reduced wear of machine cutter head face plate and tools, and all wear parts of the muck removal system;
· improved stability of tunnel face, with consequently better control of ground movements;
· improved flow of excavated material through the cutter head;
· reduced cutter head power requirements;
· reduced friction and heat build up in shield;
· excavated material formed into a suitably plastic mass;
· enhanced properties of soil in the pressure chamber of earth-pressure balance (EPBM) machines, leading to:
more uniform pressures in the working chamber;
better control of groundwater inflow by reducing permeability;
reduction in clogging of machine head chamber;
more controlled flow of soil and water through the screw conveyor;
easier handling of excavated soil.
REASONS FOR SOIL CONDITIONING AND LUBRIFICATION
· support of excavated bore in pipe jacking, microtunnelling and HDD;
· reduction of jacking forces in pipe jacking and microtunnelling;
· reduction in the friction losses in the pipes, valves and pumps of a slurry machine system;
· better separation of spoil from slurry in a slurry machine system;
· more acceptable spoil for disposal;
· through a number of the above, improved safety for personnel working in the tunnel, particularly during cutter
changes and cutter head inspections.
FOAMS (GLOBALFOAM-HG)
The principal use of foam in tunnelling is as a soil conditioning agent in EPB machines: it may also have
applications in both slurry-type and auger-type microtunnelling systems.
Foam is produced in a tunnelling machine by a compressed air system. Foam solution and compressed air are
fed at the same pressure (typically around 8 bar) to a junction piece or mixing chamber, and then out through a
diffuser unit, conditioner or lance which converts the fairly coarse foam produced in the mixing chamber to a
micro-cellular foam. Ideally most of Lubrication and soil conditioning: state of the art review 18 the foam air pores
should be less than 1mm in diameter.
The delivery system should be mounted as close as possible to the outlet position as foam is rapidly degraded if
pumped a long distance through narrow pipes. For multiple injection ports, each port should have its own
delivery system, and these should be able to operate at up to 16 bar as an aid to clearing blockages.
POLYMERS (GLOBALCYL-46)
Polymers are essentially large, long-chain molecules formed by the linking together of large numbers of small
chemical “building blocks” or monomers. Homopolymers are achieved by polymerisation of a single basic
monomer unit, copolymers by two or more different monomers. A polymer material may exist in many different
forms, depending on the lengths of the polymer chains (measured by the molecular weight), the presence and
nature of any linking between polymer chains, and the existence or not of structured (crystalline) groups of
molecules.
GLOBALSPERSE-1/45
- GLOBALFOAM-HG
- GLOBALCRYL-46
ADDITIVE 2
ADDITIVE 1
WATER
SOLUTION
AIR
SOIL CONDITIONING EXAMPLES – EPB, FOAM PRODUCTION CONDITIONING LAYOUT SHOWING INJECTION AT CUTTERFACE, WORKING CHAMBER AND SCREW CONVEYOR
AVERAGE COMPOSITION FOR A NORMALLY USED FOAM:
- GLOBALFOAM –HG: 0.5 – 1 %
-- WATER: 5 – 10 %
-- AIR: 90 -95 %
-- GLOBALCRYL-46 (EVENTUAL): < 0.1 %
FOAMING AGENT CAN HAVE INSIDE A SMALL AMOUNT OF POLYMER TO
STABILIZE THE FOAM BUBBLES
SCHEMATIC RAPRESENTATION OF “EARTH PRESSURE BALANCE MACHINE” TBM-EPBM
A MODERN EPBM DRIVE COMBINES A KNOWLEDGE OF THREE MAIN SUBJECTS: •SOIL MECHANICS (PRESSURE SUPPORT AND SOIL CHARACTERISTICS)
•TBM TECHNOLOGY (CUTTERHEAD DESIGN, INSTALLED FORCE, ...)
•SOIL CONDITIONING ADDITIVES.
ONLY A GOOD COMPREHENSION AND INTERACTION BETWEEN THESE ASPECTS WILL RESULT IN A SUCCESSFUL TBM DRIVE AND
COMMERCIAL SUCCESS.
THE CONTROL OF FACE SUPPORT IS A MAJOR ISSUE IN EPBM TUNNELLING. CONTINUOUS SUPPORT OF THE TUNNELLING FACE
MUST BE PROVIDED BY THE EXCAVATED SOIL ITSELF, WHICH SHOULD COMPLETELY FILL THE WORKING CHAMBER. THE
REQUIRED SUPPORT PRESSURE AT THE TUNNELLING FACE WILL BE ACHIEVED THROUGH:
•THRUSTING THE SHIELD FORWARD - BY MEANS OF HYDRAULIC JACKS - AGAINST THE SOIL MASS (FORCE EQUILIBRIUM)
•REGULATION OF THE SCREW CONVEYOR-ROTATION (VOLUME EQUILIBRIUM).
THE SUPPORT PRESSURE HAS TO BALANCE THE EARTH PRESSURE AND THE WATER PRESSURE. DEPENDING ON SOIL
CHARACTERISTICS AND THE COVER TO DIAMETER RATIO (T/D) DIFFERENT TYPES OF EARTH PRESSURES ARE TO BE
DETERMINED.
POLYMERS
WATER
FOAMS
ANTI CLOGGING
ADDITIVES
EPB
(EF
NA
RC
)
SOIL CONDITIONING NEEDS OF “EPB” IN DIFFERENT GROUND TYPES (SPECIFICATION AND GUIDELINES FOR THE USE OF SPECIALIST PRODUCTS FOR MECHANISED IN SOFT GROUND AND HARD ROCK – EFNARC, 2005)
RANGE OF APPLICATION
FOR EPBM-TECHNOLOGY
EARTH PRESSURE BALANCE TECHNOLOGY HAS MADE SIGNIFICANT PROGRESS IN THE PAST 10 YEARS.
ESPECIALLY REGARDING THE EXPANSION OF ITS APPLICATION TOWARDS LOW COHESIVE TO GRAINY
GROUND CONDITIONS (SEE FIG.)
SOIL CAN BE CONDITIONED WITH:
- WATER
- BENTONITE, CLAY OR POLYMER SUSPENSION
- FOAM (SURFACTANT FOAM)
- FOAM – POLYMER MIXTURE (SURFACTANT – POLYMER – FOAM)
- POLYMER (POLYMER FOAM)
WHERE THE APPLICATION OF THE CLASSIC TUNNELLING PROCEDURE, EPB AND SLURRY SUPPORT,
ARE OVERLAPPING. THIS IS REFLECTED IN SPECIFIC DENSITIES OF THE EXCAVATED MATERIAL IN THE
EXCAVATION CHAMBER.
FOAM TYPES POLYMER ADDITIVES
Soil A B C FIR
Clay 30-80 - Anti clogging polymer
Sandy clay – silt 40-60 - Anti clogging polymer
Sand – clayey silt 20-40 - Polymer for consistency control
Sand 30-40 - Polymer for cohesiveness and
consistency control
Clayey gravels 25-50 - Polymer for cohesiveness and
consistency control
Sandy gravels 30-60 - Polymer for cohesiveness and
consistency control
Product types for EPB relative to different soils (FIR values are indicative only)
The Foam type chosen should match the properties of the soil to be excavated.
Foam type A: high dispersing capacity (breaking clay bonds) and / or good coating capacity
(reduce swelling effects);
Foam type B: general purpose, with medium stability;
Foam type C: high stability and anti segregation properties to develop and maintain a cohesive
soil as impermeable as possible.
SOIL CONDITIONING: CHOICE OF FOAM TYPES
PRODUCT PERFORMANCE REQUIREMENTS
The following product types are intended to achieve one or more effects:
• FOAM:
maintenance of pressure, fluidising effect for the soil, creation of an homogeneous soil paste, permeability
reduction, lowering of torque, reduction of soil stickiness, reduction of abrasion;
• ANTI-CLOGGING AGENTS:
mainly used for heavy clay soil;
• OTHER ADDITIVES:
structuring effect on non-cohesive soils, stabilising of foam or soil, water retention, viscosity effects;
• ANTI-ABRASION AGENTS:
to add to very abrasive soils or rock formation, to reduce wear of the cutting head and its tools, extraction
screw.
These product should be environmentally acceptable and safe to handle with normal site precautions.
GUIDELINES ON USE OF FOAM FOAM DESIGN PARAMETERS
• FOAMING SOLUTION
THE CONCENTRATION OF FOAMING SOLUTION CF IS TYPICALLY IN THE RANGE 0,5 - 5,0%, BUT SHOULD
FOLLOW THE MANUFACTURER'S RECOMMENDATIONS. THIS CONCENTRATION STRONGLY DEPENDS ON
THE AMOUNT OF WATER WHICH IS INJECTED OR WHICH IS ALREADY PRESENT IN THE SOIL AND ALSO
AFFECTS THE ACTIVITY AND STABILITY OF THE USED TUNNEL FOAM.
CF - CONCENTRATION OF SURFACTANT AGENT IN WATER (..FOAMING SOLUTION)
CF = 100 X M SURFACTANT / M FOAM SOLUTION
M SURFACTANT MASS OF SURFACTANT IN FOAMING SOLUTION
M FOAM SOLUTION MASS OF FOAMING SOLUTION
• FOAM EXPANSION RATIO “FER”
THE FER SHOULD BE AT 5 – 30. THE HIGHER THE FER, THE DRIER A GENERATED TUNNEL FOAM WILL BE.
THE WETTER A SOIL, THE DRIER A TUNNEL FOAM SHOULD BE AND VICE VERSA.
FER - FOAM EXPANSION RATIO
FER = V FOAM / V FOAM SOLUTION
V FOAM VOLUME OF FOAM AT WORKING PRESSURE
V FOAM SOLUTION VOLUME OF FOAMING SOLUTION
• FOAM INJECTION RATIO “FIR”
THE FIR CAN BE AT 10 – 80%, IN MOST CASES AROUND 30 – 60%. TO DETERMINE THE BEST FIR VALUE,
LABORATORY TESTS HAVE TO BE CARRIED OUT. THE WATER CONTENT OF THE SOIL OR THE AMOUNT
OF INJECTED WATER PLAYS AN IMPORTANT ROLE.
FIR = 100 X V FOAM / V SOIL
V FOAM VOLUME OF FOAM AT WORKING PRESSURE
V SOIL VOLUME OF IN SITU SOIL TO BE EXCAVATED
(EFNARC)
WATER SPRAY
WATER SPRAYS ARE ALSO USED TO HELP REDUCE DUST. WATER SPRAY WETS THE SURFACE OF BROKEN ROCK,
PREVENTING DUST FORMATION, AS WETTED FINE PARTICLES NORMALLY ADHERE TO THE ROCK SURFACES. THIS REQUIRES
ADEQUATE DISTRIBUTION OF WATER SPRAY NOZZLES ON THE CUTTERHEAD, AND A SUFFICIENT QUANTITY OF WATER.
IN ORDER TO MINIMISE DUST FORMATION, IT IS IMPORTANT TO ENSURE THAT THE WATER SPRAY CONTINUOUSLY WETS OUT
ALL THE ROCK SURFACES IN THE BREAKING PROCESS. THE TIMELY WETTING OF ROCK CHIPS DURING THE BREAKING
PROCESS IS NECESSARY, AS ONCE THE DUST IS AIRBORNE, WATER IS RELATIVELY INEFFECTIVE AT CAPTURING IT. DAMP
AIRBORNE DUST MAY GIVE PROBLEMS IN THE EXTRACTION VENTILATION AND DUST FILTRATION EQUIPMENT.
ONE OF THE OTHER DISADVANTAGES OF WATER SPRAY IS THAT THE HIGH WATER JET VELOCITIES WILL CREATE
ADDITIONAL AIR TURBULENCE THAT CAN CONTRIBUTE TO THE CREATION OF MORE AIRBORNE DUST.
DUST CONTROL TECHNIQUES (EFNARC)
FOAM SPRAY (GLOBALFOAM-AS + GLOBALCRYL-46 )
FOAM IS ONE OF THE MOST EFFECTIVE WAYS TO REDUCE DUST IN HARD ROCK TBM EXCAVATION BUT SHOULD ALWAYS BE
USED IN COMBINATION WITH EXTRACTION VENTILATION. THE FOAM IS INJECTED THROUGH SPECIAL PORTS LOCATED ON
THE CUTTER HEAD, AND SPREADS OUT RAPIDLY TO COVER WHOLE ROCK FACE. THE THIN FILMS OF THE FOAM BUBBLES
WET OUT BROKEN ROCK (LIKE WATER SPRAY), SO REDUCE AIR BORN DUST FORMATION. UNLIKE WATER, FOAM ATTRACTS
DUST PARTICLES AND ALSO HAS STRONG STAYING POWER, FORMING A CONTINUOUS MATRIX IN THE VOIDS OF THE
EXCAVATED ROCK. THIS FORMS A VIRTUAL SEAL WHICH CAPTURES AND BLOCKS OUT THE DUST THAT WOULD OTHERWISE
HAVE BECOME AIR BORN ON THE ROCK FACE SIDE.
FOAM APPLICATION EQUIPMENT
THE CUTTER HEAD WILL NORMALLY BE FITTED WITH A COMBINED SYSTEM THAT CAN PROVIDE WATER OR FOAM. IT IS
NECESSARY TO ENSURE THAT FOAM AND WATER ARE NOT INJECTED THROUGH THE SAME PIPES, AS THIS MAY LEAD TO
PREMATURE FOAM BREAKDOWN. ALSO NOTE THAT THE PIPE SIZE IS DIFFERENT FOR THE TWO SYSTEMS.
TAILOR MADE FOAMING PRODUCTS ARE AVAILABLE IN THE MARKET, WHICH OFFER OPTIMUM FOAMING CAPACITY AND
FOAM STABILITY, AND IN THIS REGARD, THE REQUIREMENT ON THE FOAMING PRODUCTS ARE OFTEN SOMEWHAT
DIFFERENT FROM THOSE USED FOR SOIL CONDITIONING IN EPBM. THEY SHOULD ALSO BE BIO-DEGRADABLE, AND SHOULD
NOT POSE A POLLUTION RISK TO THE ENVIRONMENT.
GLOBALCHIMICA SRL is an Italian limited liability company, etablished in 1949 and
situated in Lombardore, in the North of Italy, at 20 Km from Turin and 180 Km from
Genoa, one of the bigger port of Italy. Manufacturer of chemical products for the
building, mould making and mining/tunnelling sector, Globlachimica’s factory size is of
4.500 covered square meters on a total surface of 9.700 m2.
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GLOBALCHIMICA SRL has consolidated experience on the mains markets, exporting since
1980 in Eastern Europe, North and South America, Mid East and Southeast Asia, with an export
percentage of 60 - 70 % on the total annual sales.
Internal structure of the Company is essencial but efficent. With 10 specialized employees on
the production line, team of R&D, Commercial - Export department, and Administration.
RESEARCH AND DEVELOPMENT (R&D) : GLOBALCHIMICA SRL has a modern research
and development laboratory, for controlling raw materials and finished products. This allows, to
carry out elaborate organic syntheses independently in the preparation of special raw materials
and complex formulae.
QUALITY CONTROL: Company’s main purpose is customer satisfaction. To realize this aim,
helped from equipments endowed with very high technology, products are subjected to a
process to verify that all the mains features are satisfied (Density, Viscosity, Consistency,
Dynamometer tests, FTIR and other spectral controls, Chemical analysis, etc.).
TECHNICAL COMMERCIAL DEPARTMENT: E.P.C. CONSULTING SRL (Exclusive world) –
Manager: Lamanna Luigi Franco Beside internal commercial-export department, profitable is a
cooperation for Tunnelling and Mining sector with engineers and commercial assistants located
in ROME (ITALY).
CERTIFICATION : since the end of 2007, GLOBALCHIMICA SRL is working to develop ISO
9001 certification, obtained at the beginning of 2010.
Company is shared in 4 divisions :
•Tunneling and mining : Resins for stabilising ground/rock before and after conventional
digging or with TBM through injections.
•Building : GLOBALCHIMICA SRL produces a comprehensive range of paints, protective
coatings and special formulae for building and various purposes, including waterproofing road
planking, terrace roofs, car parks, tanks, aqueducts, protective coating of bridges, viaducts,
facings, forced ducts, corrosion-proofing of chemical and industrial plants; low, medium and
high thickness coating of industrial and domestic floors, structural consolidation of major
construction works (tunnels, bridges, viaducts, railways), monumental and civil restoration.
•Mould making : Production and marketing of Room Temperature Vulcanizing RTV2 silicone
rubbers and polyurethane rubbers for moulds and matrices. Epoxy formulae for moulds and
matrices.
•Defense : Production of special paints suited for protection and camouflage of military
equipments.
Mr. LAMANNA Luigi Franco
INDEPENDENT CONSULTANT TUNNELING , MINING AND OIL
SPECIALIZED IN MECHANIZED TUNNELING WITH HARD ROCK
TBM AND SOFT SOIL EPB SHIELDS
EXPERT AND CONSULTANT IN STRUCTURAL REINFORCEMENT
LAMANNA Luigi Franco, performs for 40 years professional consulting and technical
direction in the various sectors of civil, industrial, military, hydraulics, railway,
highway and recent years in the sector of “tunneling” and “mining” on the correct
use of special “resin” and related technologies for consolidation, repair and
maintenance of masonry, concrete, iron and wood.
Is the author of numerous scientific publications and is always engaged in the study
and development of “innovative materials” and related techniques and technologies
used.
- MAINTENANCE OF AIRPORT PAVEMENTS, ROAD TRANSPORT AND CONDUCTIVE/DISSIPATIVE PAVEMENTS
- INJECTION RESINS SYSTEM IN TUNNELLING, MINING AND CIVIL ENGINEERING
- DAMS and BRIDGS - REPAIR, PROTECTION AND REINFORCEMENT OF STRUCTURAL
CONCRETE
- SOLUTIONS FOR PRE-EXCAVATION GROUTING IN ROCK TUNNELING AND MINING
Provide strong engineering solutions for our clients by
planning, designing and supervising construction of
infrastructure projects in the fields of energy, transportation,
resources, urban and public sector development.
- Hydropower - Tunnels
- Railways - Mining
- Roads - Bridgs
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Luigi Franco, Mr. LAMANNA
132, via dei Serpenti – 00184 ROME, ITALY, U.E.
INDEPENDENT TECHNICAL CONSULTANT
Tunnelling Consultant Specialized in Mechanized Tunnelling with
Hard Rock TBM and Soft Soil EPB Shields
Expert and Consultant in structural reinforcement
E-mail: lamannaluigifranco @ gmail.com - epc.consulting.italia @ gmail.com
THE ITALIAN EXPERTS IN THE SERVICE OF SAFETY IN MINES AND TUNNELING
EXPOSURE OF OUR PRODUCTS IN INTERNATIONAL TRADE FAIRS
GLOBALCHIMICA srl
16-18, via del Boschetto
10040 LOMBARDORE (TORINO) – ITALY - U.E.
e-mail: info @ globalchimica.com
TECHNICAL AND COMMERCIAL DEPARTMENT:
DIVISIONS:
- TUNNELLING
- MINING
- OIL
- CIVIL ENGINEERING UNDERGROUND ENG.
- TBM-EPB (GREASE-SEALANTS, SOIL CONDITIONING FOAMS AND POLIMERS)
Mr. LAMANNA LUIGI FRANCO
132, via dei Serpenti – 00184 ROME – ITALY - U.E.
E-mail: lamannaluigifranco @ gmail.com epc.consulting.italia @ gmail.com
THE ITALIAN CHEMICAL INDUSTRY IN THE SERVICE OF SAFETY IN MINES AND TUNNELING
