Solutions for

TUNNELING

LAMANNA Luigi Franco

February, 2015

LAMANNA Luigi Franco

June, 2015

THE NAME PRODUCTS, DESCRIPTION AND CHARACTERISTICS:

“GLOBALFOAM-SP (Fire resistant)”CAVITY FILLING - silicon-mineral-organic formula with a high expansion capacity studied for waterproofing and consolidating friable rocks and earth, filling cracks and cavities, ducting water in water table areas. Non-toxic and self extinguishing, no production of harmful fumes.FIRE RESISTANT.

“GLOBALFOAM-WR” and “GLOBALFOAM-WR-NF (Fire resistant)”WATER SEALING - polyurethane resin extremely reactive on contact with water, suitable for sealing cracks, joints, empty spaces, as well as consolidating crushed rock or concrete areas, provided that there is humidity

“GLOBALFOAM-PU” and “GLOBALFOAM-PU-NF (Fire resistant)”WATER SEALING - polyurethane resin, self-estinguishing,, suited for sealing of cracks, joints, cavity filling, and for consolidation of crusche manufacture made of stone or cement, in presence of dampness. In contact with water starts a chimica reaction that forms a closed-cells consolidating foam, which is waterproof and has a good chimica stability. FIRE RESISTANT

“GLOBALSTONE-M” and “GLOBALSONE-LV50 (Fire resistant)”SEALING AND STRUCTURAL BONDING OF FISSURES AND CRACKS (FLEX) - STRATA CONSOLIDATION – Organic-mineral two components resin, not expansible, characterized by low viscosity, excellent chimica stability, mechanical resi stance and flexibility. Ideal for water-proofing fractured rock, consolidation of loose land and rock, crack and cavity filling. Especially suitable for bonding injection drill bolts because the resins cure within just a few minutes and the bolt can be loaded in a very short time. FIRE RESISTANT.

EXAMPLE INJECTION AND CAVITYFILLING SYSTEM

COLLAPSED MATERIAL CONSOLIDATED WITH “GLOBALFOAM-SP”

IN DRIVING TUNNELS AND WHEN WORKING THROUGH TUNNELS AND FAULT AREAS.“GLOBALFOAM-SP” IS USED TO STABILISE ROCK FORMATIONS AND SEAL OFF WATER

BEARING STRATA

GLOBALFOAM-SP

INJECTION GLOBALFOAM-SP

INJECTION OF “GLOBALSTONE-LV50” OR “GLOBALFOAM-SP” ORGANO - MINERAL FOAM FOR STRATA CONSOLIDATION:

- the product has greater penetration into cracks (0.005 inches);

-the product not only anchors iron bars but it also consolidates crumble and unstable rocks;

- the product block water inflows.

COLLAPSED COLLAPSED

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THE PNEUMATIC DRIVEN SINGLE PLUNGER PUMP FOR TUNNEL AND MINING

EXAMPLE OF CONSOLIDATION OF LAND AND ROCKS BEFORE TUNNELING

(01 - 04)

01

02

EXAMPLE OF PROTECTION OF MANUFACTURED AND STABILITY OF

'THE LAND BEFORE DIGGING A TUNNEL FOR UNDERGROUND

EXAMPLE OF CONSOLIDATION TYPE “TENT" UNDER THE ROADS AND

MANUFACTURED BEFORE DIGGING A TUNNEL FOR UNDERGROUND

“JET-GROUTING” OR CHEMICAL RESIN “GLOBALSTONE-M” OR “GLOBALSTONE-LV50”

03

04

EXAMPLE OF CONSOLIDATION OF MANUFACTURED WITH POLES TYPE “JET-GROUTING" BEFORE DIGGING A TUNNEL

FOR UNDERGROUND

EXAMPLE OF A CONSOLIDATION OF RAILWAY LINE WITH POLES TYPE “JET-GROUTING" BEFORE DIGGING A TUNNEL

FOR UNDERGROUND

“JET-GROUTING” OR CHEMICAL RESIN “GLOBALSTONE-M” OR “GLOBALSTONE-LV50”

COLLAPSED

COLLAPSED

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EXAMPLE OF TREATMENT ANDSTABILISATION OF THE TUNNEL

FACE AND AHEAD OF THE RAVELLING GROUND SECTION

TREATMENT AND STABILISATION OF THE TUNNEL FACE AND AHEAD OF THE RAVELLING GROUND SECTIONS

TBM

Schematic representation of erroneus procedures sometimes adopted when crossing fault zone. The sketch illustrates a real case in a gneiss rock mass.Tunnel collapse:1. The TBM is pulled back to remove the gneiss block; 2. the TBM starts and a first collapse occurs; 3. fast ground injections

“GLOBALFOAM-SP” are carried out; 4. the TBM restarts and a second collapse occurs with a large water inrush; 5. the TBM is permanentkly stopped.

FAULT GAUGE

SOUND GNEISS

DEEPLY FRACTUREDGNEISS

INJ ECTION OF “GLOBALFOAM-SP”

RESIN

BORINGS L= 8,00 M. FOR TREATMENTS AND DRAINAGE

LANDSLIDE TREATMENTS

PRE-POST INJECTIONDRAINAGE BORING L = 5-10-15-20 M

UMBRELLA PILES L = 15-20 M

FIBERGLASS MICROPILE

TB

M-E

PB

PHASE 1 – STABILIZATION AT THE FACE

- Removal of soil from the TBM- Boring to drain water at the invert arch- Boring and spilings valved pipes L = 1.50 to 3.00 m.- Injections with resins

L = 3.00 m

L = 1.50 m

LANDSLIDE OF COHESIONLESS MATERIAL WATER INFLOWS

BORINGS L = 8.00 mFOR TREATMENTS AND DRAINAGE

TBM

PHASE 1

PHASE 2 – PILOT TUNNEL EXCAVATION AND TREATMENT

- Soil reinforcement with spiling and resins injections- Excavations of pilot tunnel and support with ribs and forepoles- Drainage borings in crows

L = 1.50 m

TYPICAL CROSS-SECTIONPILOT TUNNEL IN CROWN

FOREPOLES

SHOTCRETE & MESH AT THE

FACE

TBM

GLOBALFOAM-SP INJECTION

PHASE 2

TB

M-E

PB

PHASE 3 – PILOT TUNNEL TREATMENTS AND TBM FACE RESTORATION

- Boring and reinforcement injections from the pilot tunnel, in advancement and at TBM face- If necessary, drainage borings and umbrella forepoles at the face of pilot tunnel

TYPICAL CROSS-SECTIONPILOT TUNNEL IN CROWN

SPILINGS UNP 100, IPE 100 (L = 3.00 M)

FOAM INJECTION

PILES

L = 1.50 mL = 3.00 m

L = 6.00 m

TBM

GLOBALFOAM-SP INJECTION

PHASE 3

PHASE 4 – IF NECESSARY, DOWN EXCAVATION AT TBM FACE TO REDUCE SOIL PRESSURE ON THE HEAD

- The plan indicates a general procedure, adapted to the encountered conditions during the excavation

TYPICAL CROSS-SECTIONPILOT TUNNEL IN CROWN

SIDE PILOT TUNNEL

TBM

SW

ELLING R

OCKS

SHOTCRETE & MESH AT THE FACE

DOWN-EXCAVATION

GLOBALFOAM-SP INJECTION

GLOBALFOAM-SP INJECTION

PHASE 4

PHASE 5 – PILOT TUNNEL TREATMENT AND TBM FACE RESTORATION- Down excavation at TBM face- Drainage borings and umbrella forepoles

SIDE PILOT TUNNEL

SPILINGS UNP 100, IPE 100 - L = 3.00 m

INJECTION PILES D = 1”

TBM

DRAINAGE BORING L = 15 – 20 m

N. 18 UMBRELLA PILES D. 50 mm L = 15 – 20 m

DRAINAGE BORING D 2.5 cm L = 5 – 10 m

CAP AT FACE OF PILOT TUNNEL L = 800 mm

GLOBALFOAM-SP INJECTION

PHASE 5

COLLAPSE DUE TO EXCAVATION OF THE TUNNEL HIGHWAY "LANE COVE” IN NOVEMBER 2005 IN AUSTRALIA

THE HUGE CRATER LEFT BY THE COLLAPSED SUBWAY TUNNEL IN SHENZHEN, SOUTH CHINA'S GUANGDONG PROVINCE, JULY 20, 2009. THE TUNNEL WAS STILL UNDER CONSTRUCTION WHEN THE GROUND GAVE WAY AROUND 8:00 AM ON JULY 19, LEAVING ONE WORKER SLIGHTLY INJURED AND ONE STILL MISSING

COLLAPSED

COLLAPSED

All photos illustred are copied from the WEB

EXAMPLE OF CONSOLIDATION AROUND THE FRONT OF

EXCAVATION IN THE PRESENCE OF WATER WITH A FAULT ZONE

PIPE SHILD INJECTION RESIN FOR TUNNEL LINER SEGMENTS CONSTRUCTION AND UNDERGROUND ENGINERING

TBM

WATER BEARING ZONE

INJ ECTION “GLOBALFOAM-WR” RESINFOAMS UPON CONTACT WITH WATER(One component water sealing injectionresin for cracks and fissures in rock)

INJ ECTION “GLOBALFOAM-WR” RESINFOAMS UPON CONTACT WITH WATER(One component water sealing injectionresin for cracks and fissures in rock)

INJ ECTION “GLOBALFOAM-SP” RESIN

PROBE DRILLHOLE

When the most important problem is water the basic principle of pre-ground treatment is to utilized the ground surrounnding the tunnel as a load bearing ring and make it an integral part of the primary support and lining.

This conceprt can be reached by creating a tight ground ring around the lining so that the hydrostatic pressure inthe outer permeable ground would act on the grouted ring instead of on the lining.

TB

M-E

PB

EXAMPLE OFFILLING AND SOLIFICATION

FILLING AND SOLIDIFICATIONTUNNEL LINER SEGMENTS CONSTRUCTION

TB

M-E

PB

INJ ECTION “GLOBALFOAM-SP” RESIN PROBE DRILLHOLE

EXAMPLE OFSOIL STABILILIZATION

WATERPROOFING

TB

M-E

PB

PHASE 1

ROCK THE TBM-EPB MUST STOP IMMEDIATELY

REFLUX OF THE GROUND IN CONTACT WITH TBM-EPB

PHASE 2

TB

M-E

PB

CONTROLLED EXPLOSION

ELIMINATION OF ALL LAND SURROUNDING AREA THE BLOCK OF ROCK

PHASE 3

TB

M-E

PB

GLOBALFOAM-SP INJECTION

GLOBALSTONE-LV50 INJECTIONLAND FILL

GROUND TREATMENT AHEAD OF THE FACE

Example of preventive injection of (resin injection) “GLOBALFOAM-SP” to prevent the collapse of the ground

COLLAPSED

COLLAPSED

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INJECTIONSEXAMPLE OF TESTING FOR

POLYMER “GLOBALFOAM-WR”

TEST METHODS FOR POLYMER RESINS FOR MINING AND TUNNELLING

WATER SEALING - N. PHOTO 1 ÷ 10SINGLE COMPONENT PERMANENT FLEXIBLE WATER SEALING INJECTION GROUT FOR CRACKS AND FISSURES IN CONCRETE AND ROCK

“GLOBALFOAM-WR”

N. PHOTO 2N. PHOTO 1

WATER INGRESS

N. PHOTO 3 N. PHOTO 4

N. PHOTO 5 N. PHOTO 6

FOAM POLYMER RESIN“GLOBALFOAM-WR”

N. PHOTO 7 N. PHOTO 8

N. PHOTO 9 N. PHOTO 10

IN CASE OF WATER INTRUSIONS, TRANSUDATION OR HIGH PRESSURE WATER, THE INJECTED RESIN, WITH ITS ADHESION PROPERTIES EVEN ON WET SURFACES, ASSURES A PERFECT SEALING.

PERMANENT STRUCTURAL CRACK SEALING OF UNDERGROUND STRUCTURES-TUNNELS, SHAFTS, UNDERPASSES, ECC.

FILLING OF WATER BEARING VOIDS.

SEALING OFF FLOWING WATER.

PENETRATION OF FISSURES SMALLER THAN 0,05 MM.

“GLOBALFOAM-WR” CAN BE INJECTED AS A SIMPLE RESIN, OR HAS THE OPTION TO HAVE A FASTER REACTION IN CASE OF FLOWING WATER BY ADDING A SMALL QUANTITY OF THE ACCELERATOR "CATALYST"

PURPOSE OF TEST:

BOLTING SYSTEMS FOR TUNNELLING

THE NAME PRODUCTS, DESCRIPTION AND CHARACTERISTICS:

“GLOBALSTONE-M” and “GLOBALSTONE-LV50”

- GLOBALSTONE-M (BOLTING SYSTEM FOR TUNNELLING AND MINING):SEALING AND STRUCTURAL BONDING OF FISSURES AND CRACKS - two-component silicon-mineral-organic formula with low viscosity, does not expand, with high mechanical strength. Ideal for waterproofing broken rocks, consolidating land and rocks subject to land slide, filling cracks and cavities as well as for constructions, coatings and insulating materials, for waterproofing the walls of tanks and aqueducts. Non-toxic and non-polluting.FIRE RESISTANT. - GLOBALSTONE-LV50 (BOLTING SYSTEM FOR TUNNELLING AND MINING):SEALING AND STRUCTURAL BONDING OF FISSURES AND CRACKS (FLEX) - STRATA CONSOLIDATION – Organic-mineral two components resin, not expansible, characterized by low viscosity, excellent chimica stability, mechanical resi stance and flexibility. Ideal for water-proofing fractured rock, consolidation of loose land and rock, crack and cavity filling. Especially suitable for bonding injection drill bolts because the resins cure within just a few minutes and the bolt can be loaded in a very short time. FIRE RESISTANT.

Hard Rock TBM

GUIDE TO THE USE OF ORGANO-MINERALFOAM ROCKBOLTS

TYPE OF ANCHORED ROCKBOLTS

ADHESION

RESIN INJECTION

CEMENT

“GLOBALSTONE-LV50” AND “GLOBALSTONE-M” ORGANO-MINERAL FOAM FOR STRATA CONSOLIDATION

- CONVENIENT- SIMPLE- VERY HIGH STR. ANCHOR- PERFECT FOR VERTICAL AND OVERHEAD ROUTING

ROCKBOLTSTHESE ARE REINFORCING ELEMENTS WHICH ARE TENSIONED DURING INSTALLATION. THEY CONSIST OF A ROD AND MECHANICAL OF GROUTED ANCHORAGE (RESIN INJECTION) COUPLED WITH SOME MEANS OF APPLYING AND RETAINING THE ROD TENSION. MECHANICAL FIXING ARE SUITABLE FOR HARD ROCK, WHEREAS GROUTED, FIXED LENGTH BOLTS CAN BE USED IN MOST ROCK TYPES. THE LENGTH VARIES BETWEEN 2 TO 8 M FOR RESIN INJECTION BARS, AND 3 TO 20 M FOR AN EXPANDING SHELL FIXING ON A BAR.

“GLOBALSTONE-LV50”ORGANO-MINERAL FOAM FOR STRATACONSOLIDATION

-The product has greater penetration intocracks (0.005 inches);

-The product not only anchors iron bars butit also consolidates crumble and unstable rocks;

- The product block water inflows.

GLOBALSTONE - NON-FLAMMABLERESIN CARTRIDGE - FLAMMABLE

YES

NO

NO

YES

Rock disaggregation between bolts extends nearly to bolt anchorage

NONO

SO HERE WHAT CAN HAPPEN WHEN CARTRIDGES ARE USED FOR ANCHORING BARS

NO CARTRIDGESCEMENT

YES INJECTION CHEMICAL GROUTING “GLOBALSTONE-LV50”

ROCK BOLTING/ANCHORING

TECHNICAL AND COMMERCIALCOLLABORATION WITH THE

“GLOBALCHIMICA”

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 SHIELDSEXPERT 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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EXPOSURE OF OUR PRODUCTS IN INTERNATIONAL TRADE FAIRS

PARTS OF THE WORLD WHERE HE WAS PROVIDED OUR CONTRIBUTION

GLOBALCHIMICA srl

16-18, via del Boschetto10040 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 FRANCO132, 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

Luigi Franco, Mr. LAMANNA132, via dei Serpenti – 00184 ROME, ITALY, U.E.

INDEPENDENT TECHNICAL CONSULTANTTunnelling Consultant Specialized in Mechanized Tunnelling with

Hard Rock TBM and Soft Soil EPB ShieldsExpert 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