dosco introduction - civils (ndco)

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An Introduction to the Dosco Civil Tunnelling Division

An Introduction to Dosco

YOUR PARTNER FOR ALL ROUND QUALITY AND RELIABILITY

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Contents Page 1 Dosco – a company profile 3

2 Dosco - worldwide 11

3 Introduction to Civil Tunnelling 12

4 Recent events at Dosco 16

5 Case History - Heathrow – Baggage Tunnel 20

6 Case History - Sewage Scheme development 25

7 Case History - Heathrow Paddington Express development 28

8 Case History – West Runton sewage outfall tunnel 34

9 Dosco Roadheaders 39

10 Cross Passage Machine 41

11 Sample product data sheets 52

12 Contacts 59



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1. Dosco – a company profile History Dosco Overseas Engineering Limited is UK based and since 1995 a member of the Amco Corporation plc group. Located in Tuxford, Nottinghamshire, the company was founded in the early 1950's by the Dominion Steel and Coal Company of Canada to market the Dosco Miner in the UK coal mining industry.

Situated in North Nottinghamshire, Dosco is ideally placed to serve the UK coal mining industry, and the company's early successes were linked to the mechanisation of that industry, which called for the rapid development of gate roads for longwall faces. As well as traditional boom type Roadheaders used for development, Dosco has introduced machines for use in high volume production of a range of

minerals. In addition, machines for civil construction, materials handling and mineral processing form a key part of the product range. From its inception, the company has pursued a policy of using specialist sub-contract companies to manufacture Dosco designed parts, with final assembly and testing being undertaken at the Tuxford site.

Design & manufacture The Engineering Department employs a strong team of qualified designers and support staff using the very latest computer aided design and drafting equipment, including three-dimensional solid modelling. Each new machine design is in the hands of an experienced Project Manager, backed by a pool of qualified design and detail staff. Similarly, the Purchasing Department employ buyers responsible for the purchase of proprietary items and the outside manufacture of Dosco designed components. High standards are demanded from suppliers, and professionally



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trained staff ensures that, while negotiating the keenest prices, quality and delivery are to the required standards.

The production areas include machine assembly, component sub-assembly, fabrication, machining, and refurbishing bays. Each machine is built at one assembly point by a team of highly experienced, specialist engineers, who then have an interest in a particular machine for a particular customer. The company maintains a test area including level working areas of soft and hard ground.

The areas are used for traction and loading trials, along with any ancillary testing of equipment. Part of the site is used for cutting trials to assess machines in simulated conditions. During test, data on hydraulic flow and pressure, electrical power, force, strain, temperature, noise and vibration levels is measured and analysed.

Quality Dosco is an ISO9001 registered company, and as such maintains an independent Quality Assurance Department, responsible for inspection of goods inwards, both Dosco design and proprietary parts. The department also inspects component manufacture on suppliers' premises. As well as component inspection, the department carries out a final machine inspection to ensure the quality of the product and traceability of all components. Dosco received accredited certification to IS014001 in 2002. This demonstrates Dosco’s commitment to improving their environmental and conservation performance by minimising waste, controlling pollution and protecting the industry's natural resources.

Spares back up To maintain the company's reputation for keen deliveries and ready availability of spares, the Stores stock over £3m of component parts. A 24 hour spares supply and delivery service operates within the UK, and consignment stocks are placed with selected customers. Stocks are maintained overseas in areas where considerable numbers of machines are held, with an Export Packing Department despatching parts to customers world-wide.



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Sales support Dosco's Sales and Service teams enhance the company's reputation. A pre-sales service gives advice on cutability, cutting head design and performance estimates. The sales team are able to discuss in depth the problems which prospective customers may face, and to recommend equipment for the project. The knowledge gained from a whole range of applications over a long time period is freely available. Service engineers operate regionally within UK, providing a comprehensive 24 hour cover. All are experienced machine operators as well as fault finders and trained maintenance men. Many have experience of installing machines and training operators and engineering staff in several regions of the world. The depth of knowledge allows training of customers personnel either on site or at the Tuxford UK base.

Mineral Mining

In mineral mining, Dosco equipment has successfully operated in some 52 countries world-wide, including almost all the major coal producing countries. In addition to coal mining, experience has been gained in many other minerals including salt, potash, gypsum, iron ore, bauxite, and phosphates. The range of machines, from the Dintheader at 17 tonnes to the TTM100 at 150 tonnes, enables Mining Engineers to consider a Dosco machine for any mining application.



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Civil Tunnelling The rock cutting capability of Dosco equipment was quickly recognised by the construction industry as an alternative to drill and blast in tunnelling operations, and a range of machines has been developed for this purpose, including boom in shields and full face tunnel boring machines for soft to medium ground. Dosco has built an enviable reputation in the civil construction industry, providing machines for rail and metro links in major cities around the UK, including Liverpool and Newcastle as well as the underground link to Heathrow Airport's Terminal Four. Following these earlier successes in the field, Dosco extended its capability to the extent not only of supplying the cutting element but the complete tunnelling system including shield, conveyor, segment transport and segment erector. Dosco have supplied large shield machines to prestigious projects such as the Heathrow to Paddington Express Line and the extension to the Jubilee underground in London. A current project is a 6.84m diameter back-hoe in shield machine which is now being used on the development of the Channel Tunnel Rail Link (CTRL) under London, UK.

Not only boom in shield machines, but also full face tunnel boring machines (TBM's) have become part of the company's product range. A typical machine supplied for a sewage outfall tunnel under the North Sea was designed to be used in open mode with a full length belt conveyor, or in closed mode with a screw conveyor operating through a bulkhead for soft ground sections.



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Materials Handling & Mineral Processing In the Materials Handling field, Dosco has a manufacturing and sales agreement with Bridgestone of Japan for the unique pipe conveyor. Pipe conveyors transport materials in a totally enclosed environment (eliminating any spillage and contamination of the surrounding area) they are ideal where wastage and/or environmental issues are of major importance. The system design allows negotiation of steep gradients (30 degrees or more) and sharp curves. The conveyor can be curved both horizontally and vertically - allowing it to follow land/site contours. The wide range of belt materials includes food quality grade. Conveyor diameters range from 150mm to 850mm diameters. This gives volume flows of 95m3/hr up to 7,300m3/hr respectively.

Dosco has developed a range of crushers for the mining, quarrying and construction industries. Dosco manufacture high torque, slow speed, twin roll crushers, incorporating picks or cast manganese teeth. The innovative tooth design allows for rapid teeth changes, minimising downtime. The range can process from 100 - 5000 tph with installed powers of 100 kW – 500 kW. Suitable for materials up to 280 MPa compressive strength.



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A recent addition to the Materials Handling product range is a range of heavy duty “front end” shredders which reduce waste volume to a manageable size. The shredders are ideal for sheet metals, wood, plastics, some construction and demolition waste, household waste and rubber. They have solid hooked cutting discs or alternatively cast teeth for easy replacement. Special Engineering Products Special Engineering Projects form a key part of the Dosco product range. The specification of work that can be done seems endless. Just some of projects to date range from sub sea vehicles for diamond mining through to a tuyere cutter for cleaning out smelting furnaces. Projects of all sizes are carried out. Dosco offers a range of services from feasibility studies, design, installation and commissioning right through to full turnkey supply.



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World-wide support Dosco's ability to satisfy world demand is based on the early recognition of the importance of sound engineering, reliable after-sales service, and a constant presence in the field. To this end, the company has established a world-wide network of distributors and agents. As part of the drive for market penetration in certain world markets, licence agreements have been signed allowing indigenous manufacture of Dosco products, in India and in Poland.

To support needs of the coal mines in the Kuzbass region of Russia, a Dosco representative office has been opened in Kemerovo, Russia. The Dosco facility (which has been operational since March 2003 offers local support, technical advice, spares back up and after sales service, predominantly to the coal mining industry.

To offer the best possible support Russian approvals have been obtained for four key models of Dosco Roadheaders.

• Mk2B • MD1100 • LH1300 • MK3

As part of the support to new developments in Iran, a representative office was opened in Tehran on 10th June 2003. The local support includes: Technical advice, on-site support, Maintenance back up, Spares holding facility and Engineering workshop facility.

Iranian based engineers trained by Dosco personnel will be available for on site support.

Experienced Dosco Service Engineers are also able to offer back up on site, including commissioning, training and machine maintenance.

The Dosco stand at the Ugol Rossi Mining Exhibition, Novokuznetsk, Russia, June 2003



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New workshop facility As part of the continued expansion programme for Dosco an additional workshop has been built at the companies Tuxford location. Primarily for large machines the workshop which is 40m long, 25m wide and 15m high. The first machine which has been built in the new facilities is a civil tunnelling machine for a project on the Piccadilly Express Rail Link Extension, London, UK. The machine was delivered in October 2003. The second machine to be built in the new facilities is another civil tunnelling machine, this time for a project on the Heathrow High Speed Rail Link Extension, London, UK. The machine is due for delivery January 2004. Looking at the future To date, Dosco has manufactured almost 3,000 machines and recognises that machinery working under constant production pressures requires a constant commitment from the manufacturer. That is exactly what Dosco aims to provide. By consultation, collaboration, innovation, excellent engineering and service, Dosco continues to break new ground and production records.

The new workshop during construction



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2. Dosco – worldwide The table below shows the countries where Dosco machines have been supplied: Qty Country Qty Country 5 Argentina 1 Libya 20 Australia 5 Mexico 8 Belgium 1 Morocco 3 Brazil 1 Namibia 69 Canada 8 New Zealand 61 China 2 Nigeria 1 Chile 1 Northern Ireland 7 Czech Republic 13 Poland 1 Dubai 11 Romania 5 Egypt 3 Russia 1 Eire 6 Saudi Arabia 7 France 1 Slovak republic 12 Germany 6 South Africa 4 Hungary 18 Spain 58 India 6 Switzerland 4 Indonesia 1 Turkey 5 Italy 1 U.A.E 7 Japan 59 U.S.A 1 Kenya 2 Venezuela 4 Korea south 2 Yugoslavia

Machines supplied to the United Kingdom = 2395 Machines supplied to the rest of the world = 428



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3. Introduction to Civil Tunnelling Dosco design, manufacture and refurbish tunnel boring machines (TBM's), semi mechanised shields, Roadheaders and tunnelling systems for most types of strata. Complete tunnelling systems are designed and manufactured incorporating cutting element, shield, conveyor, segment transport and segment erector. All equipment is designed and manufactured to meet exacting customer specifications. Machine options for Civil Tunnelling applications include: Shields with hydraulic or electrical cutting booms to cope with soft to medium rock

conditions. Shields fitted with manual digging stations and/or back hoe combinations for use in soft

ground conditions Full face EPB machines for unstable natural ground Pipe jacking machines with a variety of cutter options Full face TBM’s for hard and soft ground Multidrill – percussive for straight line percussive drilling of small bore pipelines Special purpose tracked machines Shaft sinking machines Roadheaders with a variety of boom options Complete back up system

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The list below shows a selection of the applications where Dosco Civil Tunnelling machines have been utilised: Customer or location Equipment Application Qty Balfour Beatty Backhoe Shield Rail 1 Balfour Beatty Backhoe Shield Rail 1 Taywood/Costain Backhoe Shield Metro 1 Amco Boom/Shield Sewer 1 Bradford Boom/Shield Sewer 1 Citra Australia Boom/Shield Sewer 1 Citra Australia Boom/Shield Sewer 1 Liverpool M E P A S. Boom/Shield Sewer 1 Manchester Boom/Shield Sewer 1 Miller Boom/Shield Transport 1 Miller Boom/Shield Sewer 1 Newcastle on Tyne Boom/Shield Metro 3 Paris, France Boom/Shield Water 1 Redcar Boom/Shield Water 2 Scotland Glasgow Boom/Shield Sewer 1 Stoke on Trent Boom/Shield Sewer 1 Bradford Boom/Shield Sewer 1 Bristol Boom/Shield Sewer 1 Bristol Boom/Shield Sewer 1 Bristol Boom/Shield Sewer 1 British Coal Boom/Shield Mine 1 Czech Republic Boom/Shield Metro 1 Grays Boom/Shield Water 1 Heathrow Express Boom/Shield Rail 1 Heysham Boom/Shield Water 1 London Boom/Shield Metro 3 Manchester Boom/Shield Sewer 1 Mansfield Kier Boom/Shield Sewer 1 Mansfield Kier Boom/Shield Sewer 1 McAlpine Boom/Shield Sewer 1 Midsomer Norton Boom/Shield Sewer 1 Palermo Sicily Boom/Shield Water 1 Palermo Sicily Boom/Shield Water 1 Ramsgate Boom/Shield Sewer 1 Rochester Boom/Shield Waste 1



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Customer or location Equipment Application Qty Selby Boom/Shield Mine 2 Sheffield (Don Valley) Boom/Shield Sewer 1 Sheffield (Don Valley) Boom/Shield Sewer 1 Switzerland Boom/Shield Road 4 Taywood/C Boom/Shield Metro 1 Wavertree Park, Liverpool Boom/Shield Sewer 1 Arabian Tunnels Saudi Arabia Continuous miner Road 1 EPB Conversion Thurrock E.P.B.M. Sewer 1 A E Yates Micro bore Gas 1 Rees Hough Micro bore Sewer 1 Balfour Beatty NATM Rail 1 Alnniraibid Saudi Arabia Roadheader Road 2 Alnniraibid Saudi Arabia Roadheader Road 1 Andre Borie France Roadheader Sewer 1 Australia Roadheader Sewer 2 Auxini Spain Roadheader Water 1 Balfour Beatty Roadheader Rail 1 Balfour Beatty Roadheader Rail 1 Barking UK Roadheader Water 1 Bristol Roadheader Sewer 1 Bristol Roadheader Water 2 Bristol Roadheader Sewer 1 Corean Spain Roadheader Water 1 Downers New Zealand Roadheader Road 2 Dumez France Roadheader Sewer 1 Italy Roadheader Water 1 Libya Roadheader Sewer 1 Liverpool link line Roadheader Rail 2 Liverpool loop line Roadheader Rail 3 New Zealand Roadheader Water 1 Ocisa Spain Roadheader Water 1 Ocisa Spain Roadheader Water 1 Rainbow MALTA Roadheader Trench 1 Turkey Roadheader Water 2 U S A Roadheader Sewer 1 U S A Harlan tunnels Roadheader Road 1 Venezuela Roadheader Water 2 W I P P. U S A. Roadheader Waste 1 Korea Seoul Metro Roadheader Metro 2



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Customer or location Equipment Application Qty Korea Seoul Metro Roadheader Metro 1 Korea Seoul Metro Roadheader Metro 1 Saltash Plymouth Roadheader Road 1 Tarnco Saudi Arabia Roadheader Road 1 Dutco-Brochier Shaft Sinker Sewer 1 McAlpine Cromer T.B.M. Sewer 1 TBM Conversion - Dufermline T.B.M. Sewer 1 TBM Conversion - London T.B.M. Drain 1 TBM Conversion Dundee (HR) T.B.M. Sewer 1 TBM Conversion London T.B.M. Cable tunnel 2 TBM Conversion Thurrock T.B.M. Sewer 1



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4. Recent events at Dosco Pipe Conveyor in Cement application Dosco have designed and supplied two off pipe conveyors for handling cement at the RMC owned Chelm Cement Plant located in Chelm, Poland. The pipe conveyors are both 300m diameter and 200m long. They are part of a dual system each carrying up to 325 tonnes/hour of cement, 14 hours per day. The new pipe conveyors, which are part of an investment to improve and upgrade the plant were erected by Polish main contractors EZO. Other mechanical parts were procured in Poland by Dosco’s Polish office. The design work was carried out in the UK at Dosco’s head office in Tuxford. Sourcing products locally in Poland enabled Dosco’s UK skills and engineering expertise to be combined with the economies of local manufacture. The pipe conveyor system has replaced an old conventional troughed belt conveyor. It has already proved to be an efficient and cleaner system with lower maintenance costs. Pipe conveyor handles woodchips

Dosco have recently designed, supplied and commissioned a twin pipe conveyor handling woodchips at a paper plant in the Czech Republic. Main site contractor for the project was FMW, Austria for the end client Frantschach Pulp and Paper’s STETI plant in the Czech Republic.

The pipe conveyors are both 350mm diameter. Conveyor lengths are 376m and 547m. Both are capable of transporting woodchips at a rate of 250 tonnes/hour (720m3/hr). The system incorporates variable speed drives to adjust the conveyors’ fill rate and velocity and is automatically controlled by a belt weigher on the incoming conventional feed belts. The set up gives optimum efficiency and operational savings.

The layout includes curves and inclines – both vertical and horizontally, which negotiates a complex route through the site at Steti. Many structural supports and mountings from existing plant were utilised. The conveyors discharge at heights of 38m (line 1) and 50m (line 2).

As main contractor, FMW procured the steelwork locally and erected the system utilising the Dosco designs and specifications. From receipt of order the equipment was designed, manufactured, installed and commissioned by Dosco Engineers within 6 months.



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Roadheaders for Iran Dosco Overseas Engineering Ltd, an Amco Corporation Plc group company, has been awarded a contract to supply four new Roadheaders for use in the development of a major new coal mine at Tabas in IRAN. Dosco won the contract against strong overseas competition. Deciding factors in the selection of the Dosco MD1100 Roadheader included its versatility, ability to work in difficult ground conditions and the machines impressive reliability record in the field. Dosco’s ability to offer a rapid supply of the machines was also a major factor. Tabas mine located in the Parvadeh coalfield in the north eastern part of IRAN, will be the first fully mechanised underground mine in the country. The new mine is scheduled to produce 750,000 tonnes of saleable coking coal each year. The coal will be used by the mines owners and operators the National Iranian Steel Corporation (NISCO), to feed its steel making operations at Esfehan. Throughout the project Dosco will be working closely with Cementation Skanska who are the contractor responsible for providing specialist mining services for main contractor IRITEC/IRASCO.

The contract is being supplied in three stages. The first machine was completed mid June 2003, the second machine in mid July 2003 and the third and fourth machines by end July 2003.

The Dosco machines for Iran during manufacture

Dosco MD1100 Roadheader



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Dosco twin roll crusher for Spanish quarry

Dosco has supplied a twin roll crusher to be utilised in a Spanish quarry. The crusher is acting in a secondary stage. It will process a special mineral mix of clay, shale and sandstone from a nominal infeed of - 300 mm to give a nominal product size of 50 mm. Throughput is 1200 t/h.

The crusher has been purchased by ERAL, Equipos y Procesos, S. A. of Madrid for installation at a WBB quarry located in Castellón in East Spain. The quarry is a 3.5 million tonnes per year facility serving the Spanish ceramic industry.

The Dosco model DTR825 twin roll crusher incorporates cast manganese cutting teeth. The innovative way in which the teeth are retained allows for rapid change in situ without the need to remove the rolls. The crusher has a throat size of 2m width x 2.5 m long. Each roll is individually powered by a 200 kW motor via a Renold fluid coupling and a David Brown “G series” triple reduction gearbox.

The crusher is to be commissioned during July2003. Dosco machine for Channel Tunnel Rail Link (CTRL) A 6.84m diameter open-shield backhoe has been designed and manufactured by Dosco for use on the £107 million, Contract 103 of the Channel Tunnel Rail Link Development. The machine is being operated by a Kier Construction Ltd/ Edmund Nuttall Ltd joint venture (KNJV). A local competition organised by KNJV was held in local London schools to suggest a name for the new machine. The name selected from the hundreds of entries was “Getrude”. Weighing in excess of 250 tonnes and over 50m long Gertrude was taken in sections from Tuxford to her launch site in London. Gertrude starts her underground journey from King Cross Station in August 2003, and will excavate the 650m twin-tube tunnels as part of the Thameslink 2000 project.

Dosco crusher during installation

Dosco crusher during manufacture

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Roadheaders with on-board bolting for UK Coal The on-board bolting system for Roadheaders was designed by Dosco in conjunction with UK Coal Mining Ltd and the bolter manufacturers, Hydramatic Engineering Ltd. There are many benefits with on-board hydraulic bolting systems as opposed to the traditional hand held systems. • Hydraulic bolters give a fast bolt up time and a

consistent high torque to the bolts. This provides improved consistency in the standard of bolting and hence improved strata control.

• Reduced operator fatigue as the operation is much less physically demanding and very importantly retains the skills of the operators, who are restricted in the use of hand held machines due to hand/arm vibration.

The clever design enables the rigs and mounts to fold out of the way during cutting operations. They are then powered forwards hydraulically for the bolting operation. UK Coal now has a fleet of Dosco Roadheading machines with on-board roof and rib bolters fitted. Other machines have been modified to enable on-board bolters to be fitted underground at a later date if required.

A Dosco MD1100 Roadheader undergoing modification during June 2003 for UK Coal



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5. Case History - Heathrow Airport Baggage Tunnel The Heathrow Baggage Tunnel project was the first outing for the machine featured in Section 5 of this document. The project was to drive a 4.6m diameter, 1.2 km long tunnel designed to house a high-tech conveyor system to move baggage from Terminal 1 to Terminal 4. The tunnel route took it under all the main runways away from the air traffic above. The strata was typical London clay. In the unweathered state it is stiff to very stiff, grey fissured clay containing silt lenses. Sand and gravel may also be present. Relatively thin calcareous claystone bands occur throughout the sequence, in addition to hard cemented calcareous concentrations known as separation nodules. Project details

Dosco model TM1800S boom in-shield tunnelling machine



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The tunnel was worked from a shaft sunk on an island between taxiways in the middle of the airport apron. The machine was guided manually using laser sight marks. Throughout the project steady progress of 16m/day was maintained through the very consistent clay. The tunnel was approximately 25m below the runway level. Settlement to the runways and taxiways had to be kept below 20mm. Even more sensitive was the Piccadilly line, where the bore passed just 4m below the London Underground Tunnel. By keeping the boring shield moving continuously day and night, plus some very skilful work at the head, surface movement figures of around 10mm to 15mm were returned, which were well inside permitted tolerances. The tunnel was noted throughout its progress for its extreme cleanliness, much of which was attributed to the efficient muck away process. Machine information Boom A Dosco model TM1800S boom was utilised This comprised a 65kW electrically driven boom cutter mounted onto a pedestal frame. The mounting allows the boom to arc and lift sufficiently to cover the whole tunnel face. The pedestal was mounted onto a slew ring bearing, which is mounted on a sliding bracket. This enables the boom to move longitudinally in/out from the tunnel face sufficiently to excavate a minimum of one ring depth forwards of the shield cutting edge. All boom functions were controlled by manual lever valves. Additionally all functions were fully protected against hose burst, system failure and intensification. Shield Housed in the shield were 14 off 180mm bore x 1600mm stroke shove rams. Each shove ram could be individually selected for either shove or retract. Erector A heavy duty 3600 ring erector with vacuum pads was utilised. A heavy duty slide enabled the accurate positioning of the erector. Details of the tunnel lining are shown on page 22. Back up



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The back up system comprised 2 sledges. The first provided space for the hydraulic power pack and carried the feed magazine. The second provided space for two segment bodies, segment off loading hoist (electric) on a runway beam, 0.7m wide conveyor and space for shuttle car. A closed water cooling package was incorporated into the backup system. Tunnel lining



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Machine Specification Shield Shield o/d 4800 mm Shield length 3625 mm Face rams 4 x 180 mm bore 1400 mm stroke Shove rams 16 off Capacity @ 345 kg/cm2 861 kN Stroke 1200 mm Total thrust (all rams) 13776 kN TM1800S boom Cutting head motor 65 kW Lifting rams 2 No Lifting Force 32 kN Arcing rams 2 No Arcing force 33 kN Sumping ram 1 No Sumping ram force 119 kN

Conveyor Conveyor Troughed rubber belt Drive Hydraulic Rating 10 kW Speed 1 m/s

Hydraulic power pack Shove pump 1 No Capacity @ 345kg/cm2 64 l/min Conveyor pump 1 No Capacity @ 210 kg/cm2 32 l/min TM1800S pump 1 No Capacity @ 210 kg/cm2 124 l/min



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Electric's Shove, erector, magazine & conveyor pump 75 kW TM1800S pump 55 kW TM1800S cutter motor 65 kW Lighting 8 kW Spare capacity 26 kW Total 229 kW Installed power 300 kW



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6. Case History - Sewerage scheme development During 1999 Morgan Tunnelling (formerly Miller Tunnelling) were awarded the contract to construct a tunnel for a sewage treatment plant. This was to be constructed in a disused quarry situated on the outskirts of the town of Brixham, which is within the Torbay district in the southwest of Great Britain. Southwest Water Authority had previously been discharging untreated sewage into the sea from around the Torbay area. It was decided that all sewage should in future be treated before discharge into the sea. The raw sewage was to be diverted to the new treatment plant and then discharged to sea after treatment. The project was to enable the untreated sewage to be pumped from existing sewer pipes through a new connecting tunnel and into the new treatment plant. Tunnel information Tunnel diameter was 4.8m with a length of 475m, lined with concrete segments and pea gravel to be injected for primary fill prior to grout injection. Substantial flows of water were expected throughout (this reached 70 litres per second during tunnelling). The strata was predominately fissured limestone which contained some sandstone and clay deposits. A 50m deep shaft was sunk in the corner of the quarry from where the machine was launched. The machine was launched from the bottom of the shaft which was 7m diameter at the top opening out to 10m diameter at the base. A short back shunt was excavated to enable efficient launch and to facilitate pit bottom equipment when muck loading. Machine overview Morgan Tunnelling had retained the Dosco tunnelling machine that they had used for the “Baggage Tunnel” excavation under Heathrow International Airport in 1994 (full details are given in Section 3). After consultation with Dosco it was identified as suitable, with conversion, to carry out the new project.

Dosco model SB400 tunnelling machine used for the application



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Drill unit shown mounted on boom

The original machine incorporated a Dosco TM1800 type cutting boom. As the new application involved cutting through harder strata it was decided the boom should be converted to a SB400 type. The work required involved a major reconfiguration of the cutting boom. The original boom was mounted in the invert, whereas the new SB400 boom was a top mounted slide unit. A key advantage of the reconfiguration was that it allowed for greater capacity for loading muck and gave much greater access within the shield. Dosco proposed the use of their profile guidance system, which would ensure that overcuts were controlled by the driver thereby controlling the amount of pea gravel/grout used. The system also ensures that the driver has complete knowledge of the position of the boom especially whilst it is buried in the invert muck pile. It was decided that during the rebuild process a secondary provision should be designed for the drilling of ground found to be harder than the boom capability. Dosco’s solution was to store a drill upon the top of the scraper conveyor. To utilise the drill two special brackets were fixed to the boom. The drill could then be moved down the conveyor and picked up onto the cutting head of the boom. By engaging hydraulic drive mode (instead of the normal electric drive) the drill could be manoeuvred into any position around the tunnel face for a suitable drill and blast pattern. The machine utilised a single type SB400 boom powered by a 142 kW, water-cooled electric motor. The boom was hydraulically operated from a single joystick control mounted in front of the operator. The boom could be raised, lowered and arced from side to side and the whole assembly traversed forward and backward on the pedestal support (sledge) slides. The shield progressed forward using sixteen equally spaced cylinders pushing off the last ring erected. The rings were made up from a number of segments put in place using a rotary vacuum segment erector located in the rear of the shield.



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Machine back up system

As the machine moved forward it towed four sledges. • Sledge number 1 housed the hydraulic power

pack, electric control panels, transformer and scraper conveyor.

• Sledge number 2 provided space for the segment flat cars and a hoist to lift and transport the segments to the segment feeder.

• Sledges number 3 and 4 provided space for the segment and muck wagons as well as support for the belt conveyor and ventilation ducting and cassette. A full Fire Fighting System was incorporated within the Back-Up System.

Machine Specification SB400U boom Cutting head motor 142 kW Cutting head speed 27 or 50 rpm Lifting rams 2 No Lifting Force 110 kN Lifting ram stroke 370 mm Arcing rams 2 No Arcing force 130 kN Arcing ram stroke 330 mm Sumping ram 1 No Sumping ram force 234 kN Sumping ram stroke 750 mm Electric's Existing power pack motor 90 kW D.O.L SB400U Boom 142 kW D.O.L Hoist 7 kW D.O.L Lighting 8 kW D.O.L Conveyor 11 kW D.O.L Vacuum Pump 1.1 kW D.O.L Total installed power 259.1 kW Transformer rating 300 kVA



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7. Case History - Heathrow Paddington Express development The Heathrow Express is a high-speed rail link offering the fastest journey time between Heathrow Airport and Paddington - just 16 minutes. Its success has already resulted in the strengthening of the train sets. The project was to drive a 6.1m diameter, 7.5 km long tunnel and the development of two new underground stations, one serving Terminals 1, 2 and 3, and a second, four miles away, serving Terminal 4. For the first 18 km, the route follows the Great Western Main line to Airport Junction, near Hayes. Here, Heathrow Express trains leave the main line to enter the tunnel that sweeps underneath the heart of the airport. The strata was typical London clay.



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Machine information – main tunnel (6.1m outside diameter) A Dosco model SB400 shield type tunnelling machine was designed for construction of the 7.5km tunnel and two identical “Station shields” for the new underground stations. The model SB400 machine incorporated a single boom powered by a 142kW, water-cooled electric motor. The boom could be raised, lowered, arced from side to side and the whole boom assembly traversed forward and rearward on the sledge unit slides. A flipper arm – located under the boom gathered debris and loaded it onto the belt conveyor. The shield pushed forward using seventeen equally spaced cylinders pushing off the last ring erected. The rings were made up from a number of segments put in place using a rotary segment erector located in the rear of the shield. Tunnel lining

Type SB400 tunnelling machine – used for main tunnel



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The machine back up comprised seven sledges. • Sledge number 1 consisted of an upper and lower deck. Space for the hydraulic pumps is on

the lower level and hydraulic oil tank on the upper level. The segment feed magazine was located under the lower deck level. Mounted centrally is a hydraulically indexed ladder. The ladder carried a series of sprung loaded pawls which push each individual segment forward through the magazine. The magazine was able to hold seven segments.

• Sledge number 2 housed the segment off-loading hoist and monorail, which enabled a

segment to be off-loaded from the segment bogie and placed in the segment feed magazine. Space is provided for two segment and one grout bogie.

• Sledges number 3 to 7 provided space for the electrical control console, transformer and

isolator. Space was provided for 5 off 14m3 muck skips. These ran on the wagon wheel flanges whilst within the back up sledges. This facility allowed permanent rail to be laid loose inside the sledges. The loose rail was connected to the permanent rail in the tunnel, so as the machine advanced it pulled off the rear sledge, where sleepers were placed under it. This method gives continual railing up, allowing for a much quicker machine advance. The soil was removed from the shield by a belt conveyor, which was elevated 170 to the crown of the tunnel. It then turned horizontal for 30m and then discharged into the muck skips. Advance rates Advances of up to 60m/day were recorded during the work. The efficient muck away system was a significant contributor to this effectiveness. Machine specification Shield Outer diameter 6115 mm Overall length 7770 mm Cutting edge thickness 60 mm Diaphragm thickness 50 mm Shove rams 19 No Stroke 1400 mm Capacity 87 tonnes Total thrust @ 345 kg/cm2 1673 tonnes Shove time – extend 8 minutes - retract 3 minutes



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SB400 boom Cutting head speed 50 rpm Cutting head power 142 kW Lift rams 2 No Lifting force 110 kN Stroke 370 mm Working pressure 140 kg/cm2

Sumping ram 1 No Sumping force at cutting edge 234 kN Stroke 750 mm Working pressure 140 kg/cm2

Cutting rate (average) 110 m3/hr Erector Type Rotary ring Maximum rotation +- 2000

Speed of rotation (variable) 0-1 rpm Ram capacity 26.4 kN Stroke 400 mm Number of pick-up head rams 1 No Ram capacity 26.4 kN Stroke 100 mm Number of deflecting rams 2 No Ram capacity 16.6 kN Stroke 100 mm Erector hydraulic system pressure 140 kg/m2

Segment magazine Number of index rams 1 No Ram capacity 253 kN Stroke 1300 mm Maximum working pressure 210 kg/cm2

Segment handling hoist Type Electric Capacity 29.4 kN Hoist speed 3 & 10 m/min Travel speed 15 m/min Belt conveyor Type 1000 mm wide troughed rubber belt Type of drive Electric drum Rating 20 kW Capacity 350 tonnes/hour Speed 1-10 m/sec



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HYDRAULICS Shield Shield shove and face rams, and erector 1 No Capacity 90 l/min Working pressure 350 kg/cm2

Electric motor rating 55 kW Segment feed magazine Index ram pump 1 No Capacity 65 l/min Working pressure 210 kg/cm2

Electric motor rating 30 kW Boom Arcing, lifting and sumping 1 No Capacity 65 l/min Working pressure 210 kg/cm2

Electric motor rating 30 kW Electrics Shield 55 kW Boom 30 kW Filler pump 190 kW Hoist 3 kW Lighting 7.3 kW Belt conveyor 11 kW Spare capacity: 1 @ 7.5 kW 3 @ 10 kW

7.5 kW 30 kW

Total installed power 342kW Transformer 400 kVA



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Underground stations Two off 9.1m diameter shields were supplied and used in the construction of lined tunnels 8.4m inside diameter. The body of the shield consisted of 26 segments bolted together. The body was then lined with steel plates bolted to the segments to form a detachable steel body and tailskin. Material was excavated from the upper sections of the tunnel by “hand dig” and in the lower section a slew type back-hoe was used. The back hoe was also used to load the excavated material onto the conveyor. As the machine moved forward it towed three sledges behind it. • Sledge number 1 – had two upper platform decks used for

grouting and bolting of the upper segments • Sledges 2 and 3 – carried the rail track and loco wagons. To facilitate on-site assembly the shield was split into segments. These were then bolted and doweled together on assembly. The machine was designed to work at a maximum depth of 40m to the tunnel invert. Both shields were designed and built in just 19 weeks from the go-ahead being given.

Station shield – 9.1m outside diameter

Completed tunnel



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8. Case history – West Runton sewage outfall tunnel The West Runton outfall tunnel was originally designed as a pulled pipe in a shallow trench on the sea bed to be covered by 2m long “Taperweight” blocks and rock armour. The contractor won the contract with an alternative bid to build a tunnel. The project was to drive a 2.64m (104”) diameter, 2.2km tunnel out to sea through the following strata:

• Chalk containing flints • Pockets of silt/sand

The chalk was predominantly grade 5 (completely weathered without bedding or jointing) and grade 4 (less weathered and is friable and rubbly with some defined bedding and jointing) with areas of grade 3 (pockets of unweathered chalk within the weathered zones). The flints were found to be up to 700mm diameter (the forecast predicted 150mm diameter). Most of the length of the tunnel was subject to hydrostatic pressure from the North Sea at a minimum of 5.3m above the tunnel. Schematic of tunnel

Machine information A Dosco full face TBM with three cutter arms equipped with tungsten carbide tipped cutting tools was supplied. The three openings were fitted with hydraulically operated flood inundation doors for control or shut off of the excavated material. The shield body was articulated and housed eight shove rams and a rotary segment erector.

Sewer main 7.5m min cover between chalkhead and crown of bore in tidal range

32m deep shaft 2 x tunnel bore dia between chalkhead & crown of bore

Skin of TBM left in place

2.64m OD outfall tunnel

Sea Level



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The machine was designed to operate in two modes – EPB mode and open mode:

EPB mode – the cutter head chamber was sealed off from the main tunnel by a bolted-on bulkhead adapter. A hydraulically driven screw conveyor passed through to the cutting head chamber and controlled the rate of material discharge.

Open mode – by removing the screw conveyor and extending the belt conveyor into the excavation chamber the TBM could operate in open non-pressurised mode. The cut soil was lifted and discharged onto a 500mm wide belt conveyor, which discharged into 2.5m3 dirt wagons.

The segment erector was a rotary ring type, mounted off the shield rear diaphragm by six wheels. The bolted trapezoidal precast concrete rings comprised six segments that were fitted with a hydrophilic water sealing gasket. Tunnel lining



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Back up Equipment The back up equipment comprised 5 No sledges: Sledge No 1 provided space for the transformer and isolator (mounted above the segment feed magazine). The segment feed magazine comprised a curved section which had mounted on it a hydraulically indexed ladder. Mounted on the ladder were a series of spring loaded pawls, these could push individual segments forward, eventually cantilevering them into the tail skin building area. Sledge No 2 provided apace for the segment bogies. The segments were off loaded by a special hoist which transported them to the load point of the segment magazine. Sledges 3 to 5 provided space for the 4 No 2.5 m3

muck wagons and supported the 500mm wide belt conveyor. The belt conveyor was specially designed so that the load end could be articulated enabling it to fit into the cutter chamber when the machine was in EPB mode. To convert the machine from open to EPB mode the conveyor was retracted and the angle changed. The screw conveyor was then installed. Machine specification Shield Outer diameter 2642mm (104”) Overall length 5125 mm Articulation rams 8 No Capacity 411 kN each Stroke 125 mm Shove rams 8 No Capacity 520 kN each Stroke 1400 mm Maximum advance rate – open mode 20cm min Maximum advance rate – EPB mode 7 cm/min Cutter head Drive Hydraulic Speed Varaiable 1.73 to 3.25 rpm Torque 360 kN @ 3.25 rpm, 676 Kn @ 1.73 rpm



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Inundation Door rams (2 No) Capacity 520 kN each Stroke 450 mm Screw conveyor Type of drive Hydraulic Rating 20 kW Capacity 0 to 40.5 m3/hr Speed Variable 0 – 29 rpm

Conveyor Type 500 mm wide troughed belt Speed Variable 0 to 1.5 m/s Capacity 200 tonnes/hour Erector Type Rotary ring Rortation drive Hydraulic braked motor

Speed of rotation Variable 0 to 2.5 rpm Index Ram 1 No Capacity 161 kN Tilt Ram 2 No Ram capacity 58 kN each Longitudinal travel ram 1 No Capacity 161 kN Hydraulic power pack Cutter head drive pump 1 No Capacity 429 l/min @ 200 bar, 229 l/min @ 375 bar Shove and articulation pump 1 No Capacity @ 34.5 bar max 24.5 l/min Minimum shove time using all rams 6.2 mins Conveyor/erector pump 1 No Capacity @ 210 bar max 74 l/min Screw conveyor 1 No Capacity @ 200 bar max Variable 0 – 56 l/min Electrics Cutter head pump 185 kW Shove/articulation/conveyor/erector pump 45 kW Screw conveyor 22.5 kW Lighting 8 kW Spare capacity 30kW Total power 290.5 kW Transformer capacity 350 kVA



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Additional information The machine was designed, manufactured and delivered within 14 weeks of the order being placed. The 45 tonnes TBM was lowered in one piece nose first down the 32m deep entry shaft. The tunnel was driven on a maximum 1 in 90 downhill drive. It would have been preferred to drive the tunnel on a level or slightly uphill, but this would have meant a launch shaft twice the depth.



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9. Dosco Roadheaders Electrically or hydraulically operated cutting booms on Dosco Roadheaders are an efficient tunnelling method for soft to medium ground (up to a nominal 140 MPa compressive strength). The performance of the cutting boom is directly related to the ground conditions. Whilst material hardness is a key factor in determining efficiency the composition of the material e.g. whether the material has fractures or is massive, the strata mix of the face to be cut and the surrounding strata conditions are all crucial factors. Popular models of Dosco Roadheaders for Civil Tunnelling applications include the following: Typical specification: Model Power on cutting boom Machine weight

(nominal) MD1100 From 82 kW (axial)

From 112 kW (transverse) 33 tonnes

Mk2b From 82 kW 44 tonnes

LH1300 Up to 225 kW 58 tonnes

Mk3 From 147 kW 85 tonnes

Typical model Mk2b Roadheader Typical model MD1100 Roadheader



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Dosco Roadheaders can also be supplied complete with an on-board bolting facility, for both roof and rib bolting. This rapidly speeds up developments using roof and rib bolts as the method for tunnel lining. The rigs and mounts have been cleverly designed so that they fold out of the way during cutting operations. For the bolting operation they are then powered forwards hydraulically.

LH1400 Roadheaders complete with hydraulic on-board bolting equipment



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10. Cross Passage Machine A recently developed tracked machine, ideally suited for the economic construction of Cross Passages to link together twin tunnels. The Cross Passage Machine is highly manoeuvrable versatile. It incorporates a quick hitch facility to allow use of a rotary backhoe, cutting head, bucket or hydraulic impact hammer. A single operator can perform all machine functions. The operator can either work from a cab on the machine or control it remotely. Additional applications include production of underground sumps and stores.

Cross Passage Machine with Rotary Backhoe fitted Cross Passage Machine with cutting head fitted



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11. Sample data sheets

The following pages show data sheets for just some of

the extensive Dosco product range. For more information visit www.dosco.co.uk



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12. Contacts Your local Dosco agent:

Mr Al Leeming (e-mail: [email protected] or [email protected] ) NDCO Construction Services Inc.205, 3237 King George HwySurrey, BC V4P 1B7 Canada Tel: +1 604-535-7488 Fax: +1 604-535-7499

Key contacts at Dosco:

Mining Products Mr Philip Adrych - Export Sales Engineer, email: [email protected] Mr David Parnham - UK Sales Manager, email: [email protected] Materials Handling Mr Paul Holt - Materials Handling Manager - Pipe Conveyors, email: [email protected] Civil Tunnelling Mr David Keward - Civils Sales Manager, email: [email protected] Marketing Mrs Jackie Rhodes – Marketing Manager, e-mail: [email protected] Directors

Mr Michael Waltham, e-mail: [email protected]

Contact address Dosco Overseas Engineering Ltd, Ollerton Road, Tuxford, Newark, Nottinghamshire, NG22 0PQ, UK

Tel: +44 (0)1777 870621 Fax: +44 (0)1777 871580 e-mail: [email protected] Website : www.dosco.co.uk

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Dosco Overseas Engineering Ltd Ollerton Road, Tuxford Newark, Nottinghamshire NG22 0PQ, UK Tel: +44 (0)1777 870621 Fax: +44 (0)1777 871580 Web: www.dosco.co.uk e-mail: [email protected]

Your local Dosco agent: Mr Al Leeming NDCO Group of Companies205, 3237 King George HwySurrey, BC V4P 1B7 Canada

Tel: + 1 604-535-7488 Fax: +1 604-535-7499Email: [email protected]

Prepared: October 2003

dosco introduction - civils (ndco)

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