LAMANNA Luigi Franco March, 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
MAIN BEARING GREASES and TAIL SEALANTS THE NAME PRODUCTS, DESCRIPTION AND CHARACTERISTICS: “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-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/C-1P” • FIRST PACKING OF THE TAIL SEAL BRUSHES • GRASSO SIGILLANTE DI PRIMO RIEMPIMENTO
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
All photos illustred are copied from the WEB – ITA/AITES
EPB SOIL CONDITIONING
REASONS FOR SOIL CONDITIONING AND LUBRIFICATION
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.
· 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.
SOIL CONDITIONING EXAMPLES – EPB, FOAM PRODUCTION CONDITIONING
AVERAGE
LAYOUT SHOWING INJECTION AT CUTTERFACE, WORKING CHAMBER AND SCREW CONVEYOR
COMPOSITION FOR A NORMALLY USED FOAM:
- GLOBALFOAM –HG:
AIR
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
WATER - GLOBALFOAM-HG - GLOBALCRYL-46
ADDITIVE 1
GLOBALSPERSE-1/45
ADDITIVE 2
SOLUTION
SCHEMATIC RAPRESENTATION OF “EARTH PRESSURE BALANCE MACHINE” TBM-EPBM
WATER FOAMS
EPB
ANTI CLOGGING ADDITIVES
(EFNARC)
POLYMERS
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 CHARAC-TERISTICS AND THE COVER TO DIAMETER RATIO (T/D) DIFFERENT TYPES OF EARTH PRESSURES ARE TO BE DETERMINED.
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)
All photos illustred are copied from the WEB – ITA/AITES
APPLICATION RANGE: EPB SHIELD
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.
SOIL CONDITIONING: CHOICE OF FOAM TYPES 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.
Product types for EPB relative to different soils (FIR values are indicative only)
Soil Clay Sandy clay – silt Sand – clayey silt Sand Clayey gravels Sandy gravels
FOAM TYPES A B
POLYMER ADDITIVES
C
FIR 30-80 40-60 20-40 30-40
- Anti clogging polymer - Anti clogging polymer - Polymer for consistency control - Polymer for cohesiveness and
consistency control 25-50 - Polymer for cohesiveness and consistency control 30-60 - Polymer for cohesiveness and consistency control
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
(EFNARC)
• FOAMING SOLUTION THE CONCENTRATION OF FOAMING SOLUTION CF IS TYPICALLY IN THE RANGE 0,5 - 5,0%, BUT SHOULD FOLLOW THE MANU-FACTURER'S RECOMMENDATIONS. THIS CONCENTRATION STRONGLY DEPENDS ON THE AMOUNT OF WATER WHICH IS IN-JECTED 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, LABORA-TORY 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
All photos illustred are copied from the WEB – ITA/AITES
APPLICATION RANGE: FLUID SUPPORTED SHIELD
DUST CONTROL TECHNIQUES (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 DISTRI-BUTION 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.
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 POLLU-TION RISK TO THE ENVIRONMENT.
LAMANNA LUIGI FRANCO
Technical Sales Manager of GLOBALCHIMICA DPT Tunnel and Mining
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.
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 CONCRETE
BRIDGS - REPAIR, PROTECTION AND REINFORCEMENT OF STRUCTURAL
- SOLUTIONS FOR PRE-EXCAVATION GROUTING IN ROCK TUNNELING AND MINING
LAMANNA LUIGI FRANCO Independent Technical Consultant
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 - Railways - Roads
- Tunnels - Mining - Bridgs
THE ITALIAN EXPERTS IN THE SERVICE OF SAFETY IN MINES AND TUNNELING
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
EXPOSURE OF OUR PRODUCTS IN INTERNATIONAL TRADE FAIRS
THE ITALIAN CHEMICAL INDUSTRY IN THE SERVICE OF SAFETY IN MINES AND TUNNELING 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