Theory and experimental discussion of synchronous backfilling self-compacting concrete technology behind the segment wall of double-shield TBM

Abstract

The conventional method of urban subway tunnel excavation using a double-shield tunnel boring machine (DS-TBM) typically involves a two-stage backfilling process behind the segment wall using pea gravel and grouting. However, this method has inherent drawbacks such as uneven backfilling of pea gravel and delayed grouting, which can lead to structural issues such as segment dislocation, damage, and groundwater leakage during tunnel excavation. To address these problems, this study proposes a technical theory of synchronous backfilling self-compacting concrete backfilling material (SCCBM), considering the limitations of the conventional DS-TBM backfill method. This theory uses a specially designed wear-resistant seal plate suitable for a DS-TBM shield tail. The optimal proportion of SCCBM for backfilling the segment wall was determined based on Okamura's empirical method using anti-dispersion powder, fine stones (1–5 mm particle size), and coarse stones (5–10 mm particle size) as the basic materials. The SCCBM was designed and evaluated using various test methods, including the mini-slump, standard slump flow, standard L-box, and improved L-box tests. The engineering characteristics of the backfill material, such as initial setting time, blocking ability ratio, stone rate, and axial compressive strength, were considered during the evaluation. The results demonstrate that all indicators meet the standards for backfilling behind subway tunnel segment walls. Furthermore, an on-site synchronous backfilling SCCBM experiment was conducted to validate the feasibility and advantages of the new synchronous backfilling technology. The experiment involved observing the complete backfill process and monitoring the vertical displacement of the segment. Through these observations, the practicality and benefits of the proposed synchronous backfilling technology were confirmed.