Excavation Face Research Articles

Study on the Influence of Walnut Shell Coarse Particles on the Slurry Permeation and the Air Tightness of Filter Cake

Slurry shields rely on the formation of a compact filter cake to maintain excavation face stability and ensure construction safety. In strata with high permeability, significant slurry loss occurs, making filter cake formation and air tightness maintenance challenging. In this study, light organic walnut shell was selected as an additive coarse particle material for slurry. Slurries incorporating two types of coarse particles, sand and walnut shell, were prepared, and tests on slurry permeation and air tightness of the filter cake were conducted in three different strata. The results indicate that the addition of coarse particles effectively improves filter cake formation and air tightness in high-permeability strata. It is essential to use graded particles in highly permeable strata, with controlled maximum and minimum particle sizes. As the content of coarse particles increases, the air tightness of the filter cake initially increases and then decreases. Notably, the air tightness of filter cakes containing walnut shell is superior to those containing sand. Replacing sand with walnut shell as a slurry plugging material enhances filter cake quality in high-permeability strata. For highly permeable strata with a permeability coefficient greater than 1.0 × 10−3 m/s, an addition of 30 g/L to 40 g/L is recommended.

Size-Dependent Mechanical Properties and Excavation Responses of Basalt with Hidden Cracks at Baihetan Hydropower Station through DFN–FDEM Modeling

Basalt is an important geotechnical material for engineering construction in Southwest China. However, it has complicated structural features due to its special origin, particularly the widespread occurrence of hidden cracks. Such discontinuities significantly affect the mechanical properties and engineering stability of basalt, and related research is lacking and unsystematic. In this work, taking the underground caverns in the Baihetan Hydropower Station as the engineering background, the size-dependent mechanical behaviors and excavation responses of basalt with hidden cracks were systematically explored based on a synthetic rock mass (SRM) model combining the finite-discrete element method (FDEM) and discrete fracture network (DFN) method. The results showed that: (1) The DFN–FDEM model generated based on the statistical characteristics of the geometric parameters of hidden cracks can consider the real structural characteristics of basalt, whereby the mechanical behaviors found in laboratory tests and at the engineering site could be exactly reproduced. (2) The representative elementary volume (REV) size of basalt blocks containing hidden cracks was 0.5 m, and the mechanical properties obtained at this size were considered equivalent continuum properties. With an increase in the sample dimensions, the mechanical properties reflected in the stress–strain curves changed from elastic–brittle to elastic–plastic or ductile, the strength failure criterion changed from linear to nonlinear, and the failure modes changed from fragmentation failure to local structure-controlled failure and then to splitting failure. (3) The surrounding rock mass near the excavation face of underground caverns typically showed a spalling failure mode, mainly affected by the complex structural characteristics and high in situ stresses, i.e., a tensile fracture mechanism characterized by stress–structure coupling. The research findings not only shed new light on the failure mechanisms and size-dependent mechanical behaviors of hard brittle rocks represented by basalt but also further enrich the basic theory and technical methods for multi-scale analyses in geotechnical engineering, which could provide a reference for the design optimization, construction scheme formulation, and disaster prevention of deep engineering projects.

Development of an Automatic Rock Mass Classification System Using Digital Tunnel Face Mapping

To mitigate unforeseen incidents, such as key block failure or tunnel collapse during excavation, an appropriate support pattern that correlates with the geological conditions of the rock mass at the tunnel face should be designed. Rock mass evaluations should be conducted through geological face mapping during the construction phase, alongside predictions based on field investigations during the design phase. When marked discrepancies are identified, it is customary to convene an on-site evaluation involving a committee of experts. This study develops a digital tunnel face mapping system that utilises mobile devices to facilitate online evaluations during the construction phase. This system effectively replaces the traditional on-site field evaluation method. Tunnel face mapping can be promptly accomplished using images captured at the excavation face, enabling rapid analysis. In conjunction with the mapping capabilities, the developed system was designed to digitally store geological information, which includes parameters such as rock strength distribution, the spacing and length of discontinuities observed during the mapping process, as well as data pertaining to weathering and the groundwater conditions of those discontinuities. This information was then correlated with the rock mass rating sheet to automate the determination of ratings for each parameter, ultimately leading to a conclusive classification of the rock mass quality. By employing this system for tunnel face mapping and rock quality evaluation, we significantly reduced the discrepancies in the evaluation results that often arise due to the subjective judgement of geologists, as well as human errors that can occur throughout the rating process.

Mechanical Characteristics of Deep Excavation Support Structure with Asymmetric Load on Ground Surface

The purpose of this paper is to capture the mechanical response of the support structure of deep excavation subject asymmetric load. A two-dimensional (2D) numerical analysis model was established by taking a pipe gallery deep excavation subject to asymmetric load as an example. The numerical analysis results were in good agreement with the measured data, thus verified the validity of the numerical model. On this basis, the stress and displacement of support structure caused by the change in foundation asymmetric load were studied. According to the numerical results, horizontal displacement of the diaphragm wall (DW) was dominant, and the maximum horizontal displacement of the DW was 7.54 mm when the deep excavation was completed. With the increase in asymmetric load, the left wall displacement continued to increase, while the displacement of the right DW continued to decrease, and the maximum horizontal wall displacement occurred near the excavation face. The DW was the main bending component, and the maximum wall bending moment when the deep excavation was completed was 173.5 kN·m. The maximum wall bending moment increased with the increase in asymmetric load, and the maximum wall bending moment on the left of the deep excavation was greater than that on the right. The inner support sustained the main component of axial force, with the axial force peaking at 1051.8 kN when the deep excavation was completed. The axial force of the inner support increased with increasing the asymmetric load, and the axial force of the second inner support was obviously greater than that of the first inner support. This research has a positive effect on the design and optimization of deep excavation support structure subject to asymmetric load on ground surface.

Super-large diameter slurry shield tunnel encountering boulder formation: Detection, treatment and data analysis

Boulders pose substantial challenges in coastal urban tunnel engineering. This study, for the first time, utilizes extensive closely spaced borehole data from 3486 drilling points obtained during actual tunnelling through boulder strata to evaluate the effectiveness of microtremor detection, analyze variations in operational parameters, and assess the efficiency of blasting treatment. Additionally, leveraging borehole data, a 3D reconstruction of the soil-boulder-bedrock stratum was developed, and the stratum content ratio at the excavation face was derived. A multivariate linear regression model was established to explore the relationship between boulder geology and construction parameters. The results demonstrated that microtremor surveys effectively identified boulder distributions by analyzing horizontal-to-vertical spectral ratio curves and differences in surface wave phase velocity. Field drilling confirmed the high accuracy of microtremor predictions, particularly in areas with dense or thick boulder layers. Post-blasting secondary drilling revealed boulder fragments smaller than 30 cm, meeting the operational requirements for shield cutter and crusher systems. The presence of boulders was found to increase thrust, torque, and overturning moments, as well as cause abnormal cutter wear. Blasting significantly reduced the standard deviation of operational data, demonstrating its effectiveness in stabilizing tunnelling performance. Regression analysis showed a strong correlation between geological conditions and tunnelling parameters, with results indicating that blasting operations effectively mitigate the adverse impacts of boulders on shield tunnelling performance. This study aims to provide valuable insights and references for future engineering projects encountering similar complex geological conditions.

Detecting soil mixing, grain size distribution, and clogging potential of tunnel excavation face by classification-regression algorithms using EPBM operational data

Earth pressure balance machine (EPBM) operation is sensitive to the properties of the excavated soil due to the requirements of proper soil conditioning and maintenance of necessary chamber pressure. However, soil properties are invariably only available at a limited number of borehole explorations and soil samplings conducted during the subsoil investigation. Thus, it is crucial to identify properties of the tunnel excavation face, such as clay-sand mixed conditions, grain size distributions, and clogging potential along the whole alignment beside the few borehole locations to attain optimally efficient EPBM operation. Therefore, this paper presents the development of machine learning prediction models (i.e., classifiers and regressors) to estimate the properties of the tunnel excavation face using EPBM operational data collected during the tunneling operation as input features. Geotechnical data collected from boreholes and soil samples can be used to validate prediction models and calibrate them. To develop such models, the Northgate Link Extension (N125) tunneling project, constructed in Seattle, Washington, the USA, is used to capture and identify the true ground conditions. The results indicate successful prediction performances by the models, providing indication that EPBM parameters are crucial pointers of the tunnel excavation face properties to help attain optimally efficient EPBM operation.

Numerical Simulation Study of Gas–Liquid–Solid Triphase Coupling in Fully Mechanized Excavation Faces with Variation in Dust Source Points

In view of the current situation where research on the dust diffusion laws of different dust source points is limited and the gap with the actual field situation is too large; this study employs an innovative gas–liquid–solid triphase coupling method to investigate how dust moves and spreads in the fully mechanized excavation face 431305 at the Liangshuijing Mine; focusing on both the dust field and the dust–fog coupled field. The results indicate that using the long-pressure short-suction ventilation method; dust movement in the roadway is primarily influenced by the airflow; which can be classified into vortex; jet; and return flow regions. The analysis reveals that different dust source points affect dust distribution patterns. Dust source 1 generates the highest dust concentration; primarily accumulating on the duct side and return air side of the roadway. By contrast; dust source 2’s dust mainly gathers at the heading and the front of the cutting head. Dust sources 3 and 4 show lower dust concentrations near the top of the roadway. Dust source 5 achieves the most effective dust removal; aided by airflow and a suction fan; showcasing superior dust performance. A comprehensive comparison indicates that dust source 1 has the highest overall dust concentration. Therefore; further simulation of the distribution law of dust generated at dust source 1 under the action of water mist reveals that the dust concentration near the heading face is reduced from 2000 mg/m3 under the action of single air flow to about 1100 mg/m3. At t = 5 s; the spray droplets almost cover the entire tunneling face; leading to a significant decrease in dust concentration within 10–25 m from the tunneling face. Within 40 s; both coal dust and spray droplets are significantly reduced. The field measurement results verify the accuracy of the simulation results and provide certain guidance for promoting the sustainable development of the coal industry.

Study on the evolution characteristics of coal mass spalling during coal and gas outbursts

The process of coal and gas outbursts (called outbursts for short) are commonly accompanied by coal mass spalling and fragmentation, but the formation mechanism of spalling is still unclear. To clarify this mechanism, this research constructs multi-layered combined coal-rock mass model. Based on the stress wave propagation mechanism, it’s found that outbursts initially start from ‘weak layer’. Besides, there are two significant results by analyzing the process of unloading waves formed by sudden pressure relief of the excavation face. Firstly, in the axial direction, due to the internal impact of the coal mass during the unloading wave propagation, the load shock wave is formed. The tensile stress is formed on the surface of the coal mass, resulting in rapid damage to the coal mass and even multi-layered spalling. Secondly, in the radial plane, permanent standing surfaces will be formed when the unloading wave catches up with the plastic load wave. Under effect of the unloading wave, internal impact will occur a series of load shock wave, resulting in the formation of multi-layered spalling in the radial plane. In addition, the attenuation law of the load shock wave generated by the internal impact in multi-layered coal mass is also analyzed, results showed that the thickness of coal mass spalling formed far away from the free surface will increase. Finally, the three-dimensional dynamic damage path and the spindle shape damage area formation mechanism in coal mass under external dynamic load are analyzed, which provides a new idea for elucidating the outbursts mechanism.

Enhancing ground loss rate prediction in soft-soil shield tunneling: a synergistic approach of peck back analysis and eXtreme Gradient Boosting and bayesian optimization

This study investigates the prediction of ground loss rate during soft-soil shield tunneling using Peck’s back analysis method and XGBoost model. Bayesian optimization is employed to determine optimal hyperparameters, ensuring comprehensive and efficient model tuning. The XGBoost model is compared with Random Forest (RF) and Support Vector Machine (SVM) models to benchmark its performance. The results demonstrate the superior accuracy and robustness of the XGBoost model. Also, the results show that the soil properties and the grouting factors of the excavation face affect the duration of the instantaneous settlement of the ground surface. There is a specific correlation between the depth-to-diameter ratio, the coefficient of variation in the advancing speed of the shield machine, the maximum surface subsidence, and the ground loss rate. The prediction model of the ground loss rate based on the combined approach of Peck back analysis and eXtreme Gradient Boosting and Bayesian optimization has high reliability in soft-soil layers, and this method can provide a specific reference for predicting construction risk in related projects.

Cooling effect and parameter analysis of applying heat insulation layer to tunnel regionalization in construction period based on geothermal level

The construction of high geothermal tunnels presents significant difficulties due to the abnormal rock temperature gradients, including designing a reasonable and cost-effective insulation layer as well as effective cooling measures. In this study, the rock temperature distribution, environmental temperature, and lining surface temperature of the tunnel during the construction period were analyzed through field surveys. A numerical simulation model considering ventilation and heat transfer dynamics was established based on the geothermal measurements and construction characteristics of this tunnel. After validating the 3D numerical model, the effects of installing heat insulation layers according to geothermal levels on the tunnel temperature field control were investigated. Additionally, the impacts of different insulation layer thermal conductivities (λi), ventilation air volume (Wa), and duct thermal conductivities (λd) were analyzed. The results indicate: (1) The comparison of temperature fields in tunnels with insulation layers, which is applied in the range of the rock temperature above 50 °C and without insulation layers was made. The temperature near the excavation face (TAm-1) decreases by up to 0.3% (0.5 °C), tunnel environment temperature with insulation layer applied (TAm-2) decreases by up to 4.2% (2.1 °C), the secondary lining temperature (TSec-lining) decreases by up to 10.5% (4.6 °C), and the wind temperature of air duct outlet (TAir-duct) decreases by up to 0.7% (0.5 °C). (2) The length of the insulation layer increases to the full length of the tunnel, TAm-1 continues to decline by only 0.4°C, TAm-2 by 0.5 °C, TSec-lining by 0.9 °C, and TAir-duct by 0.1 °C, which shows that it is the most economical and reasonable to apply the insulation layer only in the tunnel area where the rock temperature is higher than 50 °C. (3) As λi increases, both the tunnel environment and secondary lining temperatures exhibit linear increases, while increasing Wa and λi cause quadratic decreases and increases in tunnel temperature field parameters, respectively. (4) Range analysis of orthogonal experiments reveals that for tunnel temperature field impact level. For TAm-1, the significance order is Wa >λd >λi. And for TAm-2 and TSec-lining, the significance order is Wa >λi >λd, which can provide the more economical scheme for the insulation layer design and cooling schemes in the high ground temperature tunnel.

Research on identification method of coal-rock interface based on ground penetrating radar in the driving face of soft coal seam

Coal–rock interface recognition is one of the key challenges in advancing unmanned rapid tunneling systems. To address this, a method based on variations in ground-penetrating radar (GPR) reflection wave amplitude is proposed for identifying coal-rock interfaces in soft coal seams. A mathematical model derived from Maxwell's equations calculates the coal seam area based on the reflected wave amplitude. Experiments using a 400 MHz radar antenna show that the method achieves identification errors of 3.58 cm, 3.74 cm, and 4.23 cm for coal-to-rock ratios of 1:2, 1:1, and 2:1, respectively. In practical applications within a coal mine excavation face, the identification error is 6.64 cm. This method provides crucial data for drum height adjustment and cutting arm speed regulation in unmanned tunneling systems.

Study on the Rules of Ground Settlement and Pipeline Deformation Considering the Combined Effects of Pipeline Damage Leakage and Shield Tunneling Construction

A pipeline with long-term “hidden leakage” will greatly reduce the stability of the ground between the pipeline and tunnel in the process of tunneling through existing pipelines in unsaturated soil. Excessive settlement of the surrounding strata and pipelines can occur when the shield excavation face approaches below a pipeline, which can lead to engineering accidents. This study is based on a self-developed model experimental system for tunneling through an existing pipeline with a double-line tunnel shield. The ground settlement and pipeline deformation caused by shield construction with small-scale and no leakages are investigated. An experimental study is conducted and the accuracy of the results is verified through a comparison with theoretical solutions. The results demonstrate that there is a significant increase in ground settlement and pipeline deformation under the influence of leakage water. It is also determined that the displacement field generated by the excavation of a double-line tunnel is not simply a superposition of the displacement field generated by the excavation of a single-line tunnel. The repeated disturbances caused by the excavation of a double-line tunnel significantly influences the redistribution of the displacement field. Additionally, a three-dimensional (3D) model of shield construction considering the influence of pipeline leakage is established. This study discusses the ground settlement and pipeline deformation patterns caused by changes in the vertical and horizontal leakage diffusion ranges. The computational results indicate that the diffusion depth of a leakage is the primary factor controlling the extent of settlement.

Numerical study on Slurry-induced Fracturing Pressure of Cohesive Soil

The stability of the tunnel face during the slurry shield tunnelling is controlled by the slurry pressure in the slurry chamber, and excessive slurry pressure will cause fracturing on excavation face. In order to prevent the occurrence of slurry fracturing, it is necessary to conduct a detailed study on the slurry support pressure when the slurry fracturing occurs. In this study, the hydraulic fracturing experiment of cohesive soil samples was carried out by the self-developed hydraulic fracturing device, and the improved XFEM was used to simulate the experiment process. The influence of various factors on the fracturing pressure was analyzed, and the accuracy of the numerical simulation method was also verified. In addition, the calculation method of fracturing pressure of soft cohesive soil is obtained by fitting the influence of each factor. The results show that the improved XFEM can accurately simulate the shear failure of soft cohesive soil. The fracturing pressure increases linearly with the increase in the circumferential pressure, indicating that a higher overburden of the tunnel can help resist the initial fracturing induced by shield tunneling. The fracturing pressure increases with an increase in the unconfined compressive strength as well as the slurry viscosity. Based on the regression analysis of the numerical results, an empirical approach was proposed for estimating the slurry-induced fracturing of soil.

Effect of stress unloading rate on fine-scale deformation mechanism of rock under high osmotic pressure

To explore the influence of the working face excavation rate on the rock deformation mechanism and seepage characteristics, deformation and seepage tests of sandstone under different loading and unloading stress paths, such as constant axial pressure unloading confining pressure and loading axial pressure unloading confining pressure, were carried out. Particle Flow Code in 3 Dimensions (PFC3D) and Python were used to realize fluid-solid coupling, and numerical simulation calculations were performed along the test path to analyze the influence of the unloading rate on the fine-scale deformation mechanism and permeability characteristics of sandstone, and the relationship between crack type and permeability was obtained. A sandstone fracture mechanics model is established to analyze the stress concentration degree at the end of the branch crack of the test path. The results show that the rate of confining pressure unloading is inversely proportional to the strain. Additionally, permeability correlates with the principal stress difference in an exponential manner. Interestingly, the sensitivity of permeability to stress shows an inverse trend with the unloading rate of confining pressure. Furthermore, there exists a linear relationship between permeability and the number of cracks. During the unloading process, tensile cracks predominate, and the propagation of shear cracks lags behind that of tensile cracks. The proportion of tensile cracks decreases with the increase of the unloading rate when the axial pressure is unchanged but increases when axial pressure is added, resulting in axial compression deformation and expansion deformation along the unloading direction. These research outcomes offer theoretical insights for the prudent selection of mining rates, and they hold significant implications for mitigating water inrush disasters in deep mining operations.

Investigation and optimization heat and humidity environmental control model in construction tunnels: A multifactorial approach incorporating ventilation parameters and hot water quantity

The high rock temperature and hot water influx in the surrounding area of the tunnel construction cause an excessively humid and environment high temperature inside the excavated area of the tunnel, necessitating urgent investigations into the environmental characteristics coupled with these factors and optimizing the control scheme of the construction environment. The on-site data of the tunnel temperature, humidity fields, and external environmental parameters have been collected, along with statistical analysis of the amount of the heat in the resource at the excavation face during the construction period. Subsequently, a three-dimensional numerical model coupling with high rock temperature, hot water, and ventilation was established. Based on the site monitoring data comparison, it was found that the average errors of temperature and humidity field values in the numerical simulation were 4.7 % and 7.1 %, respectively. By introducing the Heat Index (HI), the tunnel environmental characteristics under different conditions were analyzed, showing a linear relationship between the maximum HI at the excavation face and the two following features which are: the temperature-humidity of the input wind, and the hot water quantity. At the same time the air volume exhibited a quadratic relationship. Furthermore, by utilizing multivariate functions to fit the research results, the results show that the maximum HI under various conditions can be predicted. In addition, ultimately establishing an environmental safety assessment model was effective in incorporating multiple factors like input wind temperature, humidity, air volume, and hot water quantity for construction tunnels.

Mathematical modelling for strata deformation caused by rectangular pipe jacking construction in composite layered ground

In this study, analytical solutions of vertical deformation of ground surface and horizontal displacement of strata are derived combining the Mindlin solution and the mirror method due to rectangular pipe jacking tunneling in composite strata, which considers the combined effect of five factors of additional excavation pressure, friction of rectangular pipe jacking and soils, segment-soil friction, grouting filling and strata loss, respectively. The theoretical calculation results were verified against the measured data in two project cases. Moreover, effect factors of rectangular jacking pipe cross-sectional dimensions, embedment of tunnel axial depth, elasticity modulus on the interlayer and the Poisson's ratio of the interlayer on strata deformation is investigated. The results imply that the theoretical calculation values obtained using this method are more closely correlated with the observed values compared to those computed using the single stratum model. The primary cause of terrene upheaval in front of the working surface is the increased excavation pressure on the working face and the horizontal displacement of the deep soils and the surface subsidence behind the excavation face is resulting from the soil loss as the main influencing factor. The varying cross-section size of pipe jacking is able to impact on the vertical deformation of the soil, but it has a limited impact on the lateral displacement of the strata. The affection of the buried depth of the tunnel axis on strata deformation is more notable in the rectangular pipe jacking construction. As the axial tunnel depth growth, the ground surface maximum subsidence value gradually decreases, while the crest value of horizontal distortion mildly increases. When the rise of the interlayered modulus of elasticity, the maximum earth surface subsidence enlarged gradually while the subsidence trough slight diminution. Moreover, the greatest horizontal displacement exhibits a relatively minor fluctuation, but there is a trend of upward movement in the position. The influence of Poisson's ratio of the interlayer on the strata deformation is comparatively weak.

Model Design and Application for Excavation Face Stability in Upward Shield Tunneling

Model Design and Application for Excavation Face Stability in Upward Shield Tunneling

A novel dual swirling air curtain dust-control system: Design and similar experiment

The excessive concentration of dust in fully-mechanized excavation face (FEF) poses a serious risk to the health and safety of workers. This paper proposes a novel dual swirling air curtain (DSAC) dust-control system and conducts similar experiments to evaluate its effectiveness. Firstly, the theory of annular swirling jet and the dust-control mechanism of DSAC are elaborated upon. The subsequent section presents a comprehensive description of the proposed DSAC, outlining its design and the theoretical computations involved. Thereafter, the formation and attenuation of the air curtain, as well as the dust diffusion patterns with and without the DSAC system, are investigated using a similar experimental platform. The results showed that the DSAC can produce a clockwise rotating swirling air curtain. Furthermore, the utilization of the DSAC can effectively mitigate dust concentration on the experimental platform and suppress dust diffusion.

Research on the Twin-Link Stepping Temporary Support Mechanism and the Repeatable Supportability of the Roof in the Underground Excavation Roadway of Coal Mine

The coal mine’s underground heading roadway suffers from a lack of effective temporary support, which contributes to low efficiency and inadequate safety in excavation operations. This paper presents a novel approach for roadway excavation, support, and anchoring, utilizing the twin-link stepping temporary support method. To address the stability requirements of the roadway roof in this support method, a numerical model of the excavation face was developed using the BBM (Bonded Block Model) method in 3DEC 7.0 software. Through numerical simulation, the repeatability of the twin-link stepping temporary support process was assessed for various roadway roof rock types, thicknesses, and burial depths. By considering aspects such as roof fragmentation, roof convergence, and relative displacement between the direct roof and the bedrock, the range of roadway roof repeatability was determined. The proposed twin-link stepping temporary support process, along with its applicable roof conditions, establishes a theoretical foundation for implementing the parallel operation mode in coal mine underground heading roadways, thereby significantly enhancing safety and efficiency.

Stability analysis of tunnel face considering the shape of excavation and reinforcement measures

In mountain tunnels, a series of advanced reinforcement measures are often employed to maintain the stability of the tunnel face, particularly in challenging geological conditions. However, there is a lack of design theories regarding the advanced support structure for uniquely shaped tunnel faces, necessitating further exploration. Based on the limit equilibrium method, this paper presents a derivation of the mechanical model for analyzing excavation face stability considering shape changes and bolts. Additionally, a design theory for horizontal glass fiber bolts in longitudinally inclined tunnel faces is established. The reinforcement effect of the pipe shed is further considered. Finally, the proposed model is validated, and parameter analysis is conducted to guide design practices.