1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“

April 7-9, 2011, Dubrovnik, Croatia

Optimization of Supports in a Road Tunnel through

Conglomerate during Construction

Tülin SOLAK, Temelsu International Engineering Services Inc., Turkey,

tulin.solak@temelsu.com.tr
Bülent ULUKAN, Temelsu International Engineering Services Inc., Turkey,
b.ulukan@temelsu.com.tr
Göktuğ SIREL, Temelsu International Engineering Services Inc., Turkey,
gsirel@temelsu.com.tr

Summary
Ground characterization during design and construction of a tunnel determines
support applications. For the formations such as conglomerate exhibiting intact rock
and discontinuities application of standard characterization methods brings difficulties.
Due to the uncertainties in ground characterization, the re-design process has to
continue during the construction. In this paper the adaptation of tunnel design to
construction in a road tunnel is given emphasizing the characteristic of tunneling
through conglomerate. The design considerations of the Tunnel are checked during
construction. Back analyses are performed with the first deformation readings to
determine the representative ground parameters. As a result of further analysis
support system is modified in terms of bolt length and size of steel ribs to optimize
tunnel construction.

Keywords: observational method, back analysis, conglomerate, ground

characterization

Introduction
Observational method in geotechnical field consists of review of the design
considerations during construction with the aid of geotechnical measurements and
modifications of design to meet actual conditions. Application of the method in
tunneling is widened parallel to progress of NATM applications. According to the main
concept of NATM the ground is allowed to deform enabling to activate its carrying
capacity with flexible support systems.

Conglomerate is a clastic sedimentary rock which contains clast of rock particles in

matrix. This formation is generally characterized with particle composition of clast,
matrix and their bond. While the formation does not include intact rock and
discontinuities its characterization and design parameter determination bring
difficulties.

Gori Tunnel is located on Liakhvi Bridge-Ruisi Road Section in Georgia and being
constructed under the supervision of Temelsu International Engineering Services Inc.
The requirement of the adaptation of support system during construction in the Gori
Tunnel, which is presented as a case in the paper, has both technical and financial
reasons. Due to the budget constraints of the Client-Georgian Road Authority, Temelsu
International Engineering Services Inc. had reviewed as consulting, construction
 1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“
April 7-9, 2011, Dubrovnik, Croatia

process and tunnel design and recommended adaptation of support system to actual
condition. The paper consists of related evaluation and analysis performed by the
consultant engineer. In the first part of the paper the experiences in tunneling through
conglomerate from several projects are summarized and the design concept of the
Gori Tunnel in Georgia is given. In second part the conditions encountered in tunnel
construction and results of back analysis based on the first deformation
measurements are presented. Finally the modifications in tunnel support and auxiliary
measures are determined for an optimum tunnel construction. The criteria for ground
characterization are given to determine the excavation and support classes in the
Tunnel.

Tunnelling through conglomerate

Cases from design and construction

Characterization of the ground is the first step of the tunnelling through any media.
The tools used for the ground characterization should meet the requirements of
formation. For rock masses exhibiting discontinuities or soil formations ground
characterization methods differ from each other. There are also difficulties to
characterize formations in between such as conglomerate. There are not
straightforward methods or techniques to handle the design in such formations. The
experiences and findings from several projects are summarized firstly to have a
general view.

In San Vicente Pipeline Tunnel (USA) a part of tunnel is located in mixed face
conditions that includes Friars Formation Conglomerate overlying granitic rock. The
conglomerate exhibits a wide range of strength characteristics depending on the clast
compositions, degree of matrix cementation, and grain size distribution. The
parameters used to characterize the conglomerate were: the density of the formation,
the gradation of the clasts, the amount and degree of cementation of the matrix, the
strength of the clasts, and the groundwater conditions. Stand up time tests performed
for the nearby Tunnel excavated in conglomerate were analyzed. The observations
generally indicated that stand up time would be good above the groundwater level
and less favorable below the groundwater level. Firm to slow raveling ground was
anticipated above the groundwater table and slow to fast raveling ground was
anticipated below the groundwater table. Where the conglomerate matrix is very
weak, cobble and boulder clasts are not firmly held in place by the matrix, and it was
expected that the clasts would fall from the tunnel roof, sidewalls, and face if not
supported. Ground support for this class includes shotcrete and lattice girder
structural support with presupport measures including drain holes, spiling, self-drilling
tube spiles, and pipe umbrellas as required. During construction support system and
advance length is arranged according to the conditions. Probe holes were drilled with
minimum of 20 feet ahead of the face at all times. These probe holes also acted as
drain holes. Groundwater levels have been drawn down by the tunnel excavation
ahead of the tunnel face and this drawdown has tended to improve tunnel stability .
[1]. In design of the Devil’s Slide Tunnel, (USA) the conglomerate is described as light
to dark gray, weathering to dark brown, medium to coarse-grained with lithic
fragments, strong, hard, subangular to well-rounded clasts consisting of granodiorite,
quartz, sandstone, siltstone, and claystone. Conglomerate is moderately to intensely
weathered. The behavior types expected are defined with two failure modes. First one
is progressive stress induced failure mode, where the rock mass undergoes
progressive failures from shear stresses, resulting in progressive deformations as the
load bearing capacity of the rock mass is exceeded. Second one is groundwater
induced failure mode ahead of the tunnel face showing progressive failure induced by
stresses ahead of the tunnel face (fast raveling ground) [2].

The experience gained from tunnel constructions through conglomerate shows that
the ground behaviour or failure modes are closely related to the composition and
 1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“
April 7-9, 2011, Dubrovnik, Croatia

compactness of conglomerate. Water inflow is a major factor determining the

behaviour and makes drainage measures essential. The observed failure modes
through conglomerate are generally stress induced failure and instabilities of blocks of
conglomerate. Beside the primary supports presupport elements such as forepolings
are effectively used.

Design considerations in the Gori Tunnel

Gori Tunnel on Liakhvi Bridge-Ruisi Road Section in Georgia is a twin road tunnel with a
length of 780 m, a width of 12 m, and 40 m distance between centerlines of tubes
(Fig. 1). The geological formation through the Tunnel is described as weakly cemented
conglomerate (boulders and cobbles in clay matrix) as result of site investigations
during design process (Fig. 2). Fourteen borings were drilled and classification tests
were performed. Cement of conglomerate is clay with liquid limit of 40 %, plasticity
index of 20% and moisture content of 10.57 %. Strength properties could not be
determined with tests while sampling was not possible. Groundwater table is not
observed in boreholes [3].

Fig. 1 Cross section of the Tunnel [3]

B H -3 B H -4 B H -6
810 B H -5 E G E -2 8 10
EGE-2
800 8 00
E G E -3
E G E -3 B H -8
790 B H -8 A 7 90
E G E -4 E G E -3
780 7 80
E G E -3
E G E -4
770 E G E -2 7 7 0
E G E -4
760 7 60
B H -2 E G E -4
750
E G E -3 7 50
E G E -4
740 E G E -2 a n d E G E -3 7 40
A N 7D + 8 4 0 .0 0
7 + 7 8 0 .0C0U T 8 + 5 1 0 .0 0 8 + 5 6 0 .0 0
COVER TUNNEL CUT AND
COVER

B O U L D E R S A N D C O B B L E SE G E -2 C L A Y H A R D W IT H G Y P S U M C L A Y H A R D W IT H
E G E -1 W IT H L E A N C L A Y C R Y S TA LS AN D E G E -3 GY PSU M C R YS TALS
C ON GLO M E RATE LEN SES
C O N G LO M E R AT E O N C LA Y W EATHERED , HAR D PRO BA BLE B H :B O R E H O L E
E G E -4 C E M E N T S L IG H T L Y PRO BAB LE FAU LT U N IT B O U N D A R Y
 1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“
April 7-9, 2011, Dubrovnik, Croatia

Fig. 2 Geological Profile of the Tunnel [3]

Although the standard procedure of rock classification methods could not be followed
due to the nature of formation, conglomerate is evaluated as weak rock and RMR=25
GSI=20 was assigned. The design parameters were determined by formulations
related to the classification systems. The expected rock mass behavior is expressed
according to the ÖNORM 1993 as C3 at portal areas, C2 and B3 at the tunnel. The
support system consisting of 30 cm thick shotcrete, I 200 steel arch, rock bolts
(pattern 1.5x1.0 m for B3, 1.0x1.0 m for C2, 1.0x0.8 m for C3) were determined
according to the numerical analysis (Fig. 3) [3].

Fig. 3 Support Class C2 -Design [3]

Optimization of supports during construction

Evaluation of site conditions

Excavation and support application

at the tunnel have been started
according to the design.
Conglomerate at the tunnel face is
described as fairly cemented and it
consists of cobbles and boulders in
clay matrix (Fig.4). As the
construction proceeds and the first
deformation measurements were
taken at top heading excavation the
adaptation of the support system to
actual conditions is required. The
measurements after top heading
excavation shows that
 1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“
April 7-9, 2011, Dubrovnik, Croatia

displacements finalized after 10 days with a maximum value around 1 cm (Fig. 5).

Fig. 4 Photo of conglomerate at the tunnel

Back analysis

Considering the measurement data, excavation stages and applied support elements,
back analysis have been performed to check the design assumptions and mainly
design parameters of the ground for C2 class. The main principles of plain strain
modelling are followed in the two dimensional numerical analysis performed with
Rocscience software of Phase2. Elastoplastic material behavior for the ground is
considered. Core replacement procedure is followed to consider stage construction of
three dimensional tunnel constructions. For support application composite lining of
shotcrete (C20/25) and I beam, rock bolts (6-9 m long bolts at top heading, 6 m long
bolts at bench) are
considered.

GORI TUNNEL
EAST PORTAL NORTH TUBE

vertical d

20
15
displacement (mm)

10
5
0
-5 0 5 10 15
Fig. 5 Deformation data from measurement
station
-10
The parameters of the conglomerate giving a deformation value similar to measured
-15
one at the site are determined. The deformation value from the site is accepted as 1
cm. considering the displacements occurred until starting the measurements at the
-20 as 70 % of the displacement.
site, the measured displacements are accepted

The parameters for conglomerate giving a total vertical displacement of 1.34 cm after
top heading excavation at numerical analysis are determined; E=720 MPa, c=110 kPa,
φ = 37°, γ =22 kN/m3,ν =0.25. Yielding zone, which is defined as the zone where the
stresses after excavation exceeds shear strength of the ground, has a thickness of 4 m
p1-y
at shoulders.

horizontal

20
15
 1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“
April 7-9, 2011, Dubrovnik, Croatia

More than half of the 9 m long

bolts are drilled in rock where
there is no failure (Fig. 6). There
are no yielding at shotcrete and
rock bolts. Maximum bolt force is
0.09 MN; compared to the bolt
capacity (0.19 MN) they are
subjected to lower forces. The
maximum force occurs near
excavation. Considering the
maximum shear force and
moments calculated at the most
critical sections, shotcrete and
steel arch are subjected to
stresses rather lower than their
capacities.

Fig. 6 Outputs of back analysis-displacements-

yielding points-bolt loads

Further Analysis

Numerical analyses have been performed with ground parameters obtained from back
analysis considering the maximum overburden over tunnel (50 m).

Length of 9 m long rock bolts are

decreased to 6m. Size of the steel
arches was decreased from I200
to I160. The results show that
yielding zone has a thickness of 5
m at shoulders. 6 m long bolts go
beyond the yielding zone (Fig. 7).
Considering the forces of rock
bolts, moments and axial forces of
shotcrete and steel arch, the
support system is adequate to
fulfill its functions.

Additional analyses have been

performed for the other
excavation and support classes Fig. 7 Outputs of further analysis-
(B3 and C 3) to determine displacements-yielding points-bolt loads
modifications.

Recommended Procedure for Ground Characterization

While a common geological mapping and rock classification could not be followed in
the Tunnel, a procedure based on Austrian Guideline [4] is suggested to determine the
support and excavation classes. The content of the procedure for ground
characterization is given below.

Conglomerate belongs to clastic rocks in basic rock types. Considering data from
borings and excavation face in tunnel, rock material is coarse grained and no bedding
is observed. Accordingly significant key parameters can be determined as grain size,
 1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“
April 7-9, 2011, Dubrovnik, Croatia

cementation, strength properties,

matrix/component ratio according to Austrian Guideline 2001.

Factors influencing the rock mass behaviours in the tunnel are expressed as rock mass
bond or cementation ratio (loose or not loose), joint water, which reduced joint friction
(dry, minor inflow, major inflow). Considering those factors, the distinctive criteria for
three support classes are given in Table 1. Considering the present advance of tunnel
through conglomerate and borings, the main support class through tunnel is expected
as C2. Increase in compactness in conglomerate and dry conditions will lead to B3
class. Water inflow can result in C3 class.

Table 1 Support Classes

Key parameters Rock mass Water Support Class

bond inflow
Low matrix /component Not loose rock dry raveling B3
ratio, dominating grains mass
cobbles and boulders
Medium matrix Loose rock minor inflow squeezing C2
/component ratio, mass
dominating grains
cobbles, gravel
High matrix /component Loose rock major inflow high squeezing
ratio, dominating grains mass C3
gravel

Recommendations for Construction Activities

In a tunnel the construction activities affect also the performance of support elements.
Attention for construction activities will provide benefits rather than increasing the
capacity of the support system by increasing bolt lengths or changing bolt pattern etc.
Ring closure with the application of temporary shotcrete invert at top heading base
will enable the redistribution of ground loads. The optimum distance between top
heading, bench and invert excavation and support should be kept for the ring closure
of the whole support system in the tunnel.

Water inflow is the major factor which leads to washing out of the cement of
conglomerate and degradation. Drainage measures from tunnel face will prevent
loosening of formation and related instability problems.

Low cementation in conglomerate will also bring failure at crown and face of the
tunnel. Such failures can be prevented by adaptation of forepoling systems in terms of
spacing, length and used material i.e. pipes.
 1st International Congress on Tunnels and Underground Structures in South-East Europe „USING UNDERGROUND SPACE“
April 7-9, 2011, Dubrovnik, Croatia

Conclusion
Tunneling is a process starting from site investigation and continuing through design
stage to construction. With information gained from construction, the design
considerations should be checked and adapted to natural condition enables to
optimize tunnel construction. The tools used for this purpose are evaluation of
measurement data, geological conditions and construction activities and back analysis
using the results of those evaluations. Consultancy during tunnel construction enables
to take required actions for an optimized construction; economic and safe. Considering
the characteristics of conglomerate formation the criteria for the selection of support
classes are composition of conglomerate, rock mass bond and groundwater inflow.
Construction activities; ring closure of support system, drainage and forepolings have
positive influence on the behavior of the tunnel through conglomerate.

[1] KURILC M. (2007), MURRAY J., MUCREA M., SCHULER K., “Construction of a Mixed Face Reach
Through Granitic Rocks and Conglomerate”, RETC PROCEEDINGS, pp. 928.
[2] ILF CONSULTANTS, INC. AND EARTH MECHANICS, INC. (2005)”Geotechnical Baseline Report Devil’s
Slide Tunnel Project”
[3] AKIN PROJECT (2009), “Gori Tunnel Design Reports and Drawings”
[4] ÖGG (2001),”Guideline for the Geomechanical Design of Underground Structures with Conventional
Excavation”