A Case History of Tunnelling Through Difficult Ground

R. K. Goel1, Anil Swarup

1
Central Mining Research Institute Regional Centre, CBRI Campus, Roorkee, India

ABSTRACT

Udhampur-Katra section is the first leg of Udhampur-Srinagar-Baramulla Rail Link project. This
section is 25km long and involves construction of 7 tunnels. The 3.11 km long D-shaped Tunnel No.
1, discussed in the paper, has excavation width of about 6.5m and height approximately 8.2m. The
primary supports, generally, are steel ribs with varying spacing depending upon the rock type.
The main rock types encountered along the tunnel alignment were sandstones, clay stones, silt
stones and overburden comprising of boulders/pebbles in sandy/silty matrix. Due to presence of
swelling minerals and weak rock formation with high rock cover (up to 313m), the tunnelling has
experienced both swelling and squeezing ground conditions and the steel rib supports have buckled
from the sides. Floor heaving has also been observed frequently.
Tunnel instrumentation was carried out to study the rock and support behaviour. Simultaneously,
the rock mass classification approach was also used to study the degree of squeezing and for
estimating the support pressure and design of supports. A flexible system of support was adopted with
success.

1. INTRODUCTION

Udhampur-Katra section is the first leg of prestigious and challenging Udhampur-Srinagar-Baramulla

Rail Link project covering a total length of 287.0 km in the hilly terrain of Jammu & Kashmir state of
India. The project envisages construction of a new single line broad gauge railway with maximum
speed potential of 100km/hr with ruling gradient limited to 1 in 100.
The Udhampur-Katra section is 25km long and it involves construction of 7 tunnels, aggregating
to total length of 10 km. Out of 7 tunnels, 2 are more than 2 km long viz. Tunnel No. 1 (3.11 km) and
Tunnel No. 3 (2.5 km).
The Tunnel No. 1 has been excavated through jointed and sheared claystone and silt stone. The
tunnelling has experienced both the swelling and squeezing problems. At some locations, because of
high pressures, the steel rib supports have deformed and floor heaving has also been observed.
Central Mining Research Institute (CMRI) Regional Centre, Roorkee had carried out
instrumentation to evaluate and design the supports in Tunnel No. 1. The results of tunnel monitoring
together with the support design are presented as follows.

2. SALIENT FEATURES OF THE TUNNEL

The Tunnel No. 1 has the following features:

Shape: D-Shape
Excavated Width: 6.5m
Excavated vertical legs: App. 5.0m
Gradient of tunnel: 1 in 100

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Length of tunnel: 3110m
Supports: Double rib in weak rocks; Outer rib ISHB 150 @ 500mm c/c /
750mmc/c & inner rib ISHB 150 @1000 c/c; Arch support resting on
wall beam of ISHB 200/ISHB 150; Laggings of RCC slabs; backfill
by M10 concrete & filling between ribs by M-20 concrete.
The ground profile above the tunnel is shown in Fig. 1, which gives an idea of maximum
overburden of about 313 m around Chainage (Ch.) 3250m in the tunnel.

Figure 1. Longitudinal Section of Tunnel 1 from Ch. 2180 to 5320 (Obtained From Project)

The tunnel construction was started from the two ends, called the ‘Udhampur end’ and the ‘Katra end’.
The excavation work was carried out by conventional drill and blast using heading and benching
method.

3. THE GEOLOGY

The tunnels in Udhampur-Katra section fall in Shiwalik Group and Pleistocene to recent deposits. The
tunnels traversed through unconsolidated or poorly consolidated sediments with rocks of
upper/middle/lower Shiwalik and Murree formations. The main rock types encountered along the
tunnel alignment being thickly bedded, moderately soft, sparsely jointed sandstones, sheared clay
stones and silt stones. At places the tunnel also pass through unconsolidated overburden material
consisting of boulders, cobbles and pebbles at both ends coupled with high water table.
The region is in the vicinity of a major structural feature, i.e. Murree Thrust. Thus, geologically a
considerable length of the tunnel passed through extremely poor tunnelling media.
The clay mineral analysis carried out by CMRI at Institute Instrumentation Centre, IIT Roorkee
shows that the claystone of Tunnel 1 has montmorillonite, kaolinite and illite minerals. These clay
minerals have swelling characteristics.

4. GROUND CONDITIONS AND SUPPORT PRESSURES

The clay stone has been classified using the Q-system of Barton et al. (1974). Qualitatively the
claystone is described as sheared and highly jointed with three joint sets and random joints; joints are
closely spaced and the walls of joints are slickensided, undulating and smooth; altered joint walls
having coating of gouge material. The rock at the time of excavation is generally dry but with passage
of time becomes moist. For practical purposes, silt stone can also be grouped in the same class of clay
stone. Accordingly, the rating of various parameters of Q-system and value of Q for clay stones is
worked out (Table 1). The value of rock mass number N (defined as the stress free Q, i.e. Q with SRF
= 1) has also been given in Table 1.

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Table 1. Rock mass quality Q and rock mass number N for clay stone
Rock Type RQD Jn Jr Ja Jw N SRF Q
Claystone 10-15 12 1.5-2 4 1 0.3125-0.625 5-10 0.0312-0.125
(0.44)* (0.062)*
* - log average value

4.1 Estimation of ground conditions

The information on the ground condition is required for selection of excavation method and designing
the support system for underground openings.
Non-squeezing and squeezing ground conditions have been predicted by using following equation
proposed by Goel et al. (1995) wherein effect of tunnel size has also been considered:

H = (275 N0.33) B-0.1 metres (1)

Where H is tunnel depth or overburden in metres, N is rock mass number (stress free Q, i.e Q with
SRF =1), and B is tunnel span or diameter in metres.
Equation 1 implies that for a squeezing ground condition to occur, H > (275.N0.33)B-0.1 metres and
for a non-squeezing ground condition, H < (275 N0.33) B-0.1 metres. For rock mass number N = 0.44 and
excavated tunnel span B = 6.5m, from Eq. 1 the minimum depth for squeezing to occur is 170m.
Accordingly, the tunnel depths for various degree of squeezing are shown in Table 2.

Table 2. Prediction of degree of squeezing using N (Goel et al., 1995)

S. Degree of Squeezing Correlations for Predicting Degree Critical Tunnel depth H for
No. of Squeezing N=0.44 and B = 6.5m
1. Mild squeezing 275N0.33.B-0.1<H<450N0.33.B-0.1 170 < H <280
(ua/a =1-3%) and Jr /Ja <0.5 140m by Singh et al.
2. Moderate squeezing 450N0.33.B-0.1<H< 630N0.33.B-0.1 280 < H < 395
(ua/a =3-5%) and Jr /Ja <0.5
3. High squeezing H>630N0.33.B-0.1 395 < H
(ua/a > 5%) and Jr /Ja <0.25
Notation: N = Rock mass number (Q with SRF=1); B = Tunnel width in metres; H = Tunnel depth
in metres; ua = radial tunnel deformation, a = tunnel radius in metres, Jr = Barton’s joint roughness
number & Ja = Barton’s joint alteration number

The maximum tunnel depth is 313m at Ch. 3250m (Fig. 1) and therefore the moderate squeezing
ground condition was anticpated (Table 2). Assuming the same rock mass number N values all along
the tunnel and using Fig. 1 for the estimation of tunnel depth, degree of squeezing along the tunnel has
been estimated as follows:
• Mild Squeezing (Tunnel Depth 140 to 280m) - Ch. 2710 to 2965m; 3310 to 3480m & 3650 to
4425m (Total length 1200m)
• Moderate Squ. (Tunnel Depth 280 to 395m) - Ch. 2965 to 3310m & 3480 to 3650m (Total
length 515m)
It may be noted here that the above estimation has almost matched with the actual site
observations.

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4.2 Estimation of roof support pressure

The correlation of Goel et al. (1995) has been used to estimate the support pressures in squeezing
ground condition. The estimated support pressure for various tunnel depths are shown in Table 3.

Table 3. Estimated support pressure values

S.No. Tunnel Depth, m Support Pressure,
MPa
1 150 0.135
2 200 0.531
3 250 0.675
4 300 0.842

The above support pressure values (Table 3) are obtained after taking into consideration the correction
factor for tunnel closure as suggested by Goel et al. (1995) after allowing the tunnel to deform to
approximately 4 per cent of its size. In case the supports are not flexible, the support pressure values
shall be higher than what has been shown in Table 3.
On the basis of above empirical approach, the steel rib support of maximum capacity 0.84 MPa
with loose muck backfill which can allow 15-20 cm (3-4 % of tunnel size) of controlled radial rock
deformation has been suggested to use as primary support. Idea behind this was that the loose backfill
will absorb the rock deformations and shall reduce the load on the steel ribs. Accordingly, the steel rib
supports with loose muck backfill have been installed in the tunnel and the support behaviour has been
monitored by installing the load cells and the closure points. Subsequently, on the basis of monitoring
results, the support design has been recommended.

5. MONITORING OF ROCK AND SUPPORT BEHAVIOUR

Development of rock load on steel ribs and rib deformation were monitored. The load cells and the
closure points for measuring deformation are installed as shown in Fig. 2. Figure 3 shows the position
of face and bench at the time of installation of instruments on December 13, 2003.

Figure 2. Section showing position of load cells Figure 3. L-section showing position of
and the closure studs, Ch. 3460 & 3461m, instrumented section with heading and
Udhampur End benching faces, Udhampur End

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The data of the two load cells installed at Ch. 3461m is plotted against time and shown in Fig. 4. The
rib deformation/closure at Ch. 3461m and the face & bench advance is also shown in Fig. 4. The trend
of load and deformation in both the ribs was almost same. Therefore only the figure of load and
deformation at Ch. 3461 are shown.
Excavation work of face and bench was continuously going on after installation of instruments.
Figure 4 shows that there is almost no development of load up to 20 days. The face advance effect was
not shown by the load cells for 20 days. This is probably because the wall beam has also moved under
the influence of bench excavation and thus the wall beam could not provide the desirable reaction.
Hence, the stability of wall beam must be ensured in heading and benching method of tunnelling.
The development of load started after 20 days. Initially the rate of load development was high but
with time it has reduced. After about 140 days of observations, the rate of load development has
almost stabilized (Fig. 4). The load shown by the left and right load cells is around 58T and 70T
respectively. Considering the inner span of steel rib as 5.50m and rib spacing as 1.0m, the support
pressure works out from the load is between 2.3 to 2.5 kg/cm2 (0.23 to 0.25MPa)
Figure 4 also shows the plot between time after December 13, 2003 and the deformation or
closure. Initially the deformations were insignificant, but after 10 days it increases and continues to
increase gradually till the last observation (Fig. 4). The maximum deformation is about 25cm in about
150 days, which is about 4.5% of tunnel size (inner tunnel width 5.5m). The increase in load and
deformation is remains continued even when the face was about 90m away from the instrumented
section, i.e. about 15D.
Load Observations (Electrical) in T1 (Udhampur) at Chainage 3461m

180
Left Load Cell, Tonnes
160 Right Load Cell, Tonnes

140 Heading, m
Benching, m
120
Closure, cm
100

80

60

40

20

-20

-40
0 20 40 60 80 100 120 140 160
Time in No. of Days after December 13, 2003

Figure 4. Time vs. load, closure, face advance and bench advance, Ch. 3461, Udhampur End

The monitoring of revised support system shows that the supports are working satisfactorily.
Accordingly, the following flexible support system has been recommended.

6. THE FLEXIBLE SUPPORT SYSTEM

The primary flexible support system comprises of 20cm thick muck backfill between the rib of ISHB
150 and the excavated rock periphery to allow controlled rock deformation. In case of very small
much pieces, it was suggested that some other compressible material shall be filled so that 15-20cm
total deformation can be absorbed. The support monitoring has also been recommended to start
immediately at frequent intervals along the tunnel length.

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 It is also suggested that in case the rib deformations are increasing at an alarming rate, the rib
support shall be strengthened by double rib and concreting between the outer and inner rib. The
suggested primary flexible support system has been adopted in the tunnel without any difficulty and
worked satisfactorily.
The final concrete lining has been planned to place after the stabilisation of tunnel deformation.

7. CONCLUSIONS

From the case history of Tunnel No. 1 of Udhampur-Katra section, following conclusions are drawn:

• The tunnel is passing through the claystone and siltstone which are jointed, sheared and weak
formations.
• The claystones have swelling clay minerals indicating the presence of swelling pressure.
• The weak rock formations under high cover pressure are also experiencing the squeezing ground
conditions as demonstrated by the empirical approaches and high order of deformations.
• The deformations estimated by the empirical approach are almost matching with the observed
range of deformation. The study highlights the reliability of empirical approach and usefulness of
monitoring.
• Monitoring of load has clearly shown the development of more loads on the left side near the
parking niche, i.e. the effect of intersections has been observed.
• The development of load and deformation remains continued even when the tunnel was about 15D
away from the instrumented section.
• The flexible support system adopted in the tunnel has worked satisfactorily without any practical
difficulty.

REFERENCES

Barton, N., Lien, R., and Lunde, J. (1974). Engineering Classification of Rock Masses for the Design
of Tunnel Support, Rock Mechanics, Springer-Verlag, Vol. 6, pp. 189-236.
Goel, R.K., Jethwa, J. L. and Paithankar, A. G. (1995). Indian Experiences with Q and RMR Systems,
Tunnelling & Underground Space Technology, Vol. 10, No.1, pp. 97-109.