A D P P S: Face Support Calculation

ADELAIDE DESALINATION PROJECT
PORT STANVAC
Face Support Calculation
BABENDERERDE ENGINEERS
General
GENERAL
Babendererde Engineers was asked to calculate the face support pressure for the outfall
tunnel of Adelaide Desalination Project, Port Stanvac. The tunnel has an excavation
diameter of 3.44 m and is about 1.500 m long. Except the first 320 m, it passes below the
sea bed.
About the geology, initial 520 m tunnel is in Precambrian rock formation and then it passes
through the zone of glacial sediments for next 400 m. The rest of the section is in tertiary
deposits, consisting of different layers of silty sands, sandy clay, sandstone, limestone etc..
From the overview of the rock properties, the tunnel face in the Precambrian rock formation
seems stable. Even though to stop the water ingress, it might be necessary to apply the
support pressure to balance the water pressure. Alternatively, if the amount of water ingress
is relatively small, it could be pumped out especially in the time of intervention. For this
section, required face support pressure is calculated considering water pressure and
operation tolerance only.
Face support pressure is calculated in following four sections.
 At station 620, near to Borehole BH11M: Tunnel lies in soil layer T6. The strength
parameters of the soil layer T6 and glacial deposit (P) are similar.
 At station 800, near to Borehole BH3M: Tunnel is in glacial deposit. The calculation
is carried out with the parameters of the granular matrix as it posses less shear
strength than the cohesive matrix.
 At station 1.050, after Borehole BH4M, tunnel lies in soil type T6 and after this
section change in tunnel alignment could be seen.
 At station 1.400, near to BH6M: Tunnel is in soil T6. For the overlying soil T2, soil
parameters are taken for silty clay as it posses less shear strength than the
siltstone.
As the pressure regulation takes place with the regulation of inflow and outflow in pump, the
operational tolerance of 20 kN/m² is taken in the calculation. But for the time of drawdown it
is taken as 10 kN/m². Unit weight of the bentonite suspension is taken as 12 kN/m³ and
10.5 kN/m³ during the advance mode and drawdown mode.
For the face support calculation sea level is taken as +0.00 m as shown in the longitudinal
section provided to us. Support pressure is further calculated for the tide level of +1.00 m
07.12.2009 -1/7- www.facesupport.org

General
and + 3.00 m. In between it can be interpolated linearly. Summary of the calculation are
shown in following table. They are also plotted in the face support diagram attached in the
appendix.
Support pressure At crown in advance mode Full drawdown mode

in bar Sea level Sea level
for station +0.00 +1.00 +3.00 +0.00 +1.00 +3.00
At start 1.9 2.0 2.2 2.1 2.2 2.5
Station 500 2.9 3.0 3.2 3.1 3.2 3.4
Station 620 3.1 3.2 3.5 3.4 3.5 3.7
Station 800 3.7 3.8 4.0 3.9 4.0 4.2
Station 1.050 4.3 4.4 4.6 4.6 4.7 4.9
Station 1.400 4.5 4.6 4.8 4.7 4.8 5.0
The variation of the sea level affects the water head acting on the tunnel face. There will be
some phase difference between the variation of water level in sea and the actual water head
in the tunnel face. This time lag could not be defined with the help of the available
documents. Therefore during the time of tunnel advance, it will be meaningful to adopt
support pressure covering the maximum water level. But for the time of compressed air
intervention it will be better to consider the water level with time lag, it will help to work in
minimum possible compressed air pressure and provides longer working time.
The description of the adopted calculation method is presented below. The face support
calculations for each four sections are attached in the appendix.
Bad Schwartau, 07.12.2009
Tim Babendererde i.A. Binayak Sharma

Description of Face Support Model
DESCRIPTION OF FACE SUPPORT CALCULATION MODEL

Following two publications are taken as the basis of earth pressure calculation:
„The face stability of slurry shield-driven tunnels“, Anagnostou & Kovári, Tunnelling and
Underground Space Technology, Vol. 9, No. 2, pp. 165-174, 1994.
“Problematik der Standsicherheit der Ortsbrust beim TBM-Vortrieb im Betriebszustand

Druckluftstützung”, Holzhäuser, Babendererde Engineers GmbH, Mitteilungen des Institutes
und der Versuchsanstalt für Geotechnik der Technischen Universität Darmstadt, Heft Nr. 52,
49-62 (2000).
The calculation model is based on an approach

developed by Horn to design the breasting
elements in underground railway (1961). The
failure mechanism consists of a wedge and an
overlying prism. The front of the wedge is taken
as circumscribed square around the circle with
excavation diameter of tunnel (s. fig. 1).
The model is further improved by Anagnostou &

Kovári in the 90s adopting the “Silo Theory” of
Jahnssen and Terzaghi (1895). According to Figure 1: Failure Mechanism of HORN
this theory the effective vertical stress of the soil
is reduced due to the shear resistance in the surface of the prism.
The coefficient of lateral pressure in the region of silo is taken as the average of coefficient of
earth pressure at rest and coefficient of active earth pressure. Silo effect has to be
considered only in the soil layers with sufficient bearing capacity because the lack of
sufficient stiffness of the soft soil layer prevents the activation of shear force along the side
surfaces of the prism. Silo effect of such soil layer can be excluded taking value of lateral
earth pressure equals to zero.
Another parameter affecting the silo effect is the tunnel cover. Full silo effect has to be
considered only when tunnel cover is larger than the excavation diameter. For the smaller
covers, the silo effect will be reduced in proportional to the ratio of cover to excavation
diameter.
If the angle of the sliding wedge is too low (< 20°), the shear resistance and the silo effect will
be reduced. From 20° to 10°, the shear resistance are reduced linearly to zero. For the

angle below or equal to 10°, the side surfaces are so small that the shear force is not taken
into account.
To ensure the stability of the face, the support pressure should counterbalance the horizontal
earth pressure and the water pressure. In EPB tunnelling, the support pressure is applied
through the earth paste made of the soil from the excavation chamber and conditioning
agents. The pressure in the excavation chamber is regulated through the velocity of
advance and the discharge of screw conveyer. Additionally an operational tolerance is
added considering the precision in control of support pressure.
WATER PRESSURE
Water pressure is considered as a hydrostatic pressure.
EARTH PRESSURE
In this model, with the help of silo theory the vertical soil stress is calculated for each soil
layer. It starts with the surface loads at ground surface and calculates the vertical stress for
each soil layer up to the tunnel crown. The parameters of soil layers like unit weight, angle of
friction, cohesion, coefficient of lateral pressure and depth are taken into account. Geometry
of prism is considered with the ratio of base area to it circumference.
The soil in the tunnel face is assumed as a uniform soil layer. In the case with different soil
layers in the tunnel face, area weighted average of the
parameters like unit weight, angle of friction and
cohesion are calculated.
In the sliding wedge, the shear resistance of the sides

and back surface is taken into consideration. The
earth pressure is calculated by analysing the
equilibrium of the wedge considering weight of sliding
wedge, reduced weight of the prism and soil
Figure 2: Sliding Wedge Forces
resistance along the failure planes as shown Figure 2.
E cos   2T1 cos   G 3  G 4  sin   0 (Equation 1)
  90    
The maximum earth pressure is calculated by iteration, varying the angle of sliding wedge ω.
From the calculated earth pressure for the square face is reduced to earth pressure for
circular tunnel face with the help of ratio of circular area to the square area. The earth
pressure distribution in the face is considered as linear taking into account of the average

unit weight of soil at face, a constant coefficient of spatial earth pressure and effective
vertical earth pressure at the tunnel crown according to silo effect.
SURFACE LOADS
In the calculation, surface loads are mainly distinguished between permanent and temporary
loads. Load of the permanent structures like buildings, dams, dykes, fills etc. present on the
section will be taken under permanent load and the loads of vehicles like crane, trucks etc.
will be considered under temporary loads. Both of these loads will add earth pressure but
only the permanent load contributes against blow out and ground heaving.
For the face support calculation the lowest ground surface level is considered. The soil layer
up to maximum ground surface level is considered as temporary surface loads. In this way
the maximum cover is considered to support pressure and minimum cover for break-up and
blow out safety.
OPERATING MODES
Following four standard operating modes are analysed:
 Advance mode
 1
3 Drawdown
 1
2 Drawdown
 1
1 Drawdown
In order to facilitate the entry of persons for the inspection and if necessary, for repair and
maintenance of cutterhead, the level of earth paste has to be reduced. The support pressure
is maintained supplying compressed air.
The pressure distribution diagram for compressed air and for the earth paste as supporting
medium is different. Therefore, depending upon the operating mode a new face support
pressure should be calculated for each mode.
If the depth of specific drawdown is smaller than 2 m then it is taken as unfeasible for
hyperbaric intervention. Such cases may appear in tunnel with small diameter and it will be
marked in the calculation.
SAFETY CONCEPT
To ensure the stability of the tunnel face, it is necessary to counterbalance the total force of
active earth and water pressure applying a support pressure with the help of support
medium. Active earth pressure and water pressure are separately multiplied with safety

factors as per the concept of partial safety factor. The support pressure is calculated to
satisfy the following equilibrium condition:
S  P
  1,0 (Equation 2)
 w  W  Ε  E
Where: S = support pressure
E = active earth pressure
W = water pressure
ηw = safety factor for water pressure
ηE = safety factor for earth pressure
P = Operational tolerance
ORDINATE CHECK
To prevent the lack of equilibrium in individual local areas, critical nodes at tunnel face like at
crown and at invert level of tunnel and at the level of lower edge of compressed air are
checked individually.
In the ordinate check with partial safety

factor, the water pressure multiplied with the
allocated safety factor at the critical ordinate
should not be less than the face support
pressure in this height.
Whereas with the addition, the support

pressure should not be less than the sum of
water pressure and addition in the critical
height.
At the level of tunnel crown, a separate

Figure 3: Ordinate Check
ordinate check is also performed, taking
both earth and water pressure into account.
From the ordinate check, if it is determined that the previously calculated supporting pressure
does not meet the criteria of ordinate check then the support pressure is adjusted to fulfil the
required safety.

SAFETY AGAINST BLOW OUT AND BREAK-UP

In the tunnel with relatively small cover, the
applied support pressure may lead to ground
breaking during advance mode and blow out
of applied compressed air during drawdown.
Consequently sudden loss of support
pressure takes places. To prevent these
phenomenons, the ratio of weight of
overburden soil and water to the applied
support pressure should not be smaller than
predefined safety factor. It is an additional
safety check to be performed with the face
Figure 4: Erosion blow-out
support pressures.
E v,Crown  WCrown
  (Equation 3)
S Crown
Where: Ev,Crown = Vertical earth pressure at tunnel crown

WCrown = Water pressure at tunnel crown
SCrown = Support pressure at tunnel crown
η = Required safety factor against blow out and break-up safety
FACE SUPPORT CALCULATION

The calculation for face support and safety against break up is attached in following reports
for each section.
NOTE
The calculated face support pressure is the required pressure at the tunnel crown
(excavation chamber). The pressure to be maintained at the compressed air bubble is
shown in the chart. It is calculated considering the level of bentonite slurry at the axis of the
working chamber and the given unit weight of slurry.

SUPPORT PRESSURE / TUNNEL CROWN IN ADVANCE MODE:
[bar] 5.5
5.0 4.8 bar 4.8 bar
4.6 bar
4.5 4.6 bar
4.0 bar 4.5 bar 4.6 bar 4.5 bar
4.0 4.3 bar 4.4 bar
3.5 bar
3.5 3.2 bar 3.7 bar 3.8 bar
3.0 3.1 bar 3.2 bar
2.9 bar 3.0 bar
2.5
2.0
1.5
[Station]
500 620 800 1050 1400
SUPPORT PRESSURE IN FULL DRAWDOWN MODE:
[bar] 5.5
4.9 bar 5.0 bar 5.0 bar
5.0
4.8 bar
4.5 4.2 bar 4.6 bar 4.7 bar 4.7 bar 4.8 bar 4.7 bar
4.0 3.7 bar
3.5 3.4 bar 3.9 bar 4.0 bar
3.4 bar 3.5 bar
3.0 3.1 bar 3.2 bar
2.5
2.0
1.5
[Station]
500 620 800 1050 1400
LEGEND:
SEA LEVEL +0.00m SEA LEVEL +1.00m SEA LEVEL +3.00m
Revision Date Description Drawn by Checked by Approved by
NOTE:
Client:
THIS DRAWING IS BASED ON THE INFORMATION DOCUMENT 090304_LONGSEC_OFFSHORE (VERD PD_1) FROM SMEC AUSTRALIA PTY LTD BABENDERERDE
PLEASE USE THIS DRAWING ONLY WITH THE ORIGINAL DOCUMENT FOR LOOK TO THE QUALIFICATIONS AND NOTES
ENGINEERS
Markt 2 Phone: +49-(0)451-300939-0
D-23611 Bad Schwartau Fax: +49-(0)451-300939-29
Project:
Adelaide Desalination Outfall
Face Support Drawing
Drawing No.: Scale: Date: Drawn by: Checked by: Approved by:
09045-01 -/- 07.12.2009 NB BC TB
Name of Project: Adelaide Desalination Project

Location Name: At BH11M
Calculation Section: Station 620
1. Default Information:
- TBM Type Slurry
- Tunnel Diameter D = 3.44 m
- Depth of the Tunnel (Crown) d = 27.30 m
- Depth of Groundwater Table dGWL = 0.00 m
- Unit Weight of the Supporting Medium (advance) γb = 12.00 kN/m³
- Unit Weight of the Supporting Medium (drawdown) γb = 10.50 kN/m³
- Calculation Method Anagnostou & Kovári
- Slipwedge Critical Angle ω = 24.30 °
2. Surfaceloads:
- Permanent Surface Load = 0.00 kN/m²
- Temporary Surface Load = 0.00 kN/m²
3. Safety Coefficients:
- Operational Tolerance, Support Medium ΔpM = ± 20.00 kN/m²
- Operational Tolerance, Compressed Air ΔpCAP = ± 10.00 kN/m²
- Partial Safety Factor, Earth Pressure ηE = 1.50
- Partial Safety Factor, Water Pressure ηw = 1.05
- Blow out Safety γη,stb = 1.10
- Combined Ordinate Check, Crown Factor [-] Earth Pressure ηkF,ea = 1.30
- Combined Ordinate Check, Crown Factor [-] Water ηkF,w = 1.05
- Ordinate Check, Bottom Edge compressed air Factor [-] Water ΔPCAP, = 1.05
- Ordinate Check Invert Factor [-] Water ΔPw = 1.05
4. Miscellaneous Information:

System Structure:
26.11.2009
-2/4-
Legend:
t. Symbol for Type of Soil/Admixture γ Unit weight of the wet soil in [kN/m³] φ' Angle of Friction in [°]
h Layer Thickness in [m] γ' Submerged unit weight of the soil in [kN/m³] λ Coefficient of Lateral Pressure
d Depth soil layer bottom in [m] c' Cohesion in [kN/m²]
www.facesupport.org
Face Support Pressure:
0.0 m
Depth from 1/3 - 1/2 - 1/1 -
Advance Additional
Surface drawdown drawdown drawdown
Drawdown
[m] Face Support Pressure [bar]
Crown 27.30 3.1 3.2 3.2 3.4 3.2
Tripart Point 28.45 3.3 3.2 3.2 3.4 3.3
Axis 29.02 3.4 3.2 3.2 3.4 3.4
Invert of the Tunnel 30.74 3.6 3.4 3.4 3.4 3.5
global global global ordinate global
Critical Safety Check
safety safety safety invert safety
Safety against Heave 1.1 1.1 1.1 1.1 1.1
Execution possible.
Execution possible, but drawdown to low for intervention (≤1.5m)!
Execution not possible! Safety against blow out is less than required value.
Advance:
1/2 - Drawdown:

1/1 - Drawdown:


- TBM Type Slurry
2. Surfaceloads:

System Structure:
26.11.2009
-2/4-
Legend:
www.facesupport.org
0.0 m
Depth from 1/3 - 1/2 - 1/1 -
Advance Additional
Drawdown
Crown 32.05 3.7 3.7 3.7 3.9 3.7
Tripart Point 33.20 3.8 3.7 3.7 3.9 3.8
Axis 33.77 3.9 3.7 3.7 3.9 3.9
Execution possible.
Advance:
1/2 - Drawdown:

1/1 - Drawdown:


Location Name: After BH4M
- TBM Type Slurry
2. Surfaceloads:

System Structure:
26.11.2009
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Legend:
www.facesupport.org
0.0 m
Depth from 1/3 - 1/2 - 1/1 -
Advance Additional
Drawdown
Crown 38.50 4.3 4.3 4.4 4.6 4.3
Tripart Point 39.65 4.4 4.3 4.4 4.6 4.4
Axis 40.22 4.5 4.4 4.4 4.6 4.5
ordinate ordinate ordinate ordinate buttom edge
crown invert invert invert compressed
Execution possible.
Advance:
1/2 - Drawdown:

1/1 - Drawdown:


- TBM Type Slurry
2. Surfaceloads:

System Structure:
26.11.2009
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Legend:
www.facesupport.org
0.0 m
Depth from 1/3 - 1/2 - 1/1 -
Advance Additional
Drawdown
Crown 40.20 4.5 4.5 4.6 4.7 4.5
Tripart Point 41.35 4.6 4.5 4.6 4.7 4.7
Axis 41.92 4.7 4.6 4.6 4.7 4.7
Execution possible.
Advance:
1/2 - Drawdown:

1/1 - Drawdown:

A D P P S: Face Support Calculation

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ADELAIDE DESALINATION PROJECT

Face Support Calculation

Face support pressure is calculated in following four sections.

07.12.2009 -1/7- www.facesupport.org

Support pressure At crown in advance mode Full drawdown mode

Bad Schwartau, 07.12.2009

Tim Babendererde i.A. Binayak Sharma

07.12.2009 -2/7- www.facesupport.org

DESCRIPTION OF FACE SUPPORT CALCULATION MODEL

“Problematik der Standsicherheit der Ortsbrust beim TBM-Vortrieb im Betriebszustand

The calculation model is based on an approach

The model is further improved by Anagnostou &

07.12.2009 -3/7- www.facesupport.org

In the sliding wedge, the shear resistance of the sides

E cos   2T1 cos   G 3  G 4  sin   0 (Equation 1)

07.12.2009 -4/7- www.facesupport.org

07.12.2009 -5/7- www.facesupport.org

Where: S = support pressure

E = active earth pressure

ηw = safety factor for water pressure

ηE = safety factor for earth pressure

In the ordinate check with partial safety

Whereas with the addition, the support

At the level of tunnel crown, a separate

07.12.2009 -6/7- www.facesupport.org

SAFETY AGAINST BLOW OUT AND BREAK-UP

Where: Ev,Crown = Vertical earth pressure at tunnel crown

FACE SUPPORT CALCULATION

07.12.2009 -7/7- www.facesupport.org

Face Support Calculation

Calculation Section: Station 620

- Tunnel Diameter D = 3.44 m

- Depth of the Tunnel (Crown) d = 27.30 m

- Depth of Groundwater Table dGWL = 0.00 m

- Unit Weight of the Supporting Medium (advance) γb = 12.00 kN/m³

- Unit Weight of the Supporting Medium (drawdown) γb = 10.50 kN/m³

- Calculation Method Anagnostou & Kovári

- Slipwedge Critical Angle ω = 24.30 °

- Temporary Surface Load = 0.00 kN/m²

- Operational Tolerance, Compressed Air ΔpCAP = ± 10.00 kN/m²

- Partial Safety Factor, Earth Pressure ηE = 1.50

- Partial Safety Factor, Water Pressure ηw = 1.05

- Blow out Safety γη,stb = 1.10

- Combined Ordinate Check, Crown Factor [-] Water ηkF,w = 1.05

- Ordinate Check Invert Factor [-] Water ΔPw = 1.05

26.11.2009 -1/4- www.facesupport.org

d Depth soil layer bottom in [m] c' Cohesion in [kN/m²]

26.11.2009 -3/4- www.facesupport.org

26.11.2009 -4/4- www.facesupport.org

Face Support Calculation

Calculation Section: Station 800

- Tunnel Diameter D = 3.44 m

- Depth of the Tunnel (Crown) d = 32.05 m

- Depth of Groundwater Table dGWL = 0.00 m

- Unit Weight of the Supporting Medium (advance) γb = 12.00 kN/m³

- Unit Weight of the Supporting Medium (drawdown) γb = 10.50 kN/m³

- Calculation Method Anagnostou & Kovári

- Slipwedge Critical Angle ω = 24.20 °

- Temporary Surface Load = 0.00 kN/m²

- Operational Tolerance, Compressed Air ΔpCAP = ± 10.00 kN/m²

- Partial Safety Factor, Earth Pressure ηE = 1.50

- Partial Safety Factor, Water Pressure ηw = 1.05