TBM

Solutions for UndergroundConstruction

2

TBM
from Master Builders Solutions

Master Builders Solutions

The Master Builders Solutions brand brings all of ourexpertise together to create chemical solutions for
new construction, maintenance, repair and renovationof structures. Master Builders Solutions is built on
the experience gained from more than a century in theconstruction industry.
Our know-how and experience as a global community ofMaster Builders Solutions construction experts form thecore of Master Builders Solutions. We combine the rightelements from our portfolio to solve your specificconstruction challenges. We collaborate across areas ofexpertise and regions and draw on the experience
gained from countless construction projects worldwide.
front cover photo: © The Robbins Company

Global underground construction team

Our comprehensive portfolio

Master Builders Solutions, with its global undergroundconstruction team, provides reliable, customer-oriented
solutions focused on your needs in the tunneling andmining industries all over the world. We recognize thatyour success is underpinned by our ability to deliver
solutions that meet or exceed your critical needs. By
accompanying you from the start of your project andunderstanding the issues that are important to you, we
can contribute to your success. We support you withproduct training and quality control, and our professional
technical services team is on hand around the clock,helping you with specialist technical advice and trouble
shooting.

n Concrete admixtures
n Cement additives
n Chemical solutions for underground constructionn Waterproofing solutionsn Sealants
n Concrete repair and protection solutionsn Performance groutsn Wind turbine groutsn Performance flooring solutions

TBM
from Master Builders Solutions

We leverage global Master Builders Solutions
technologies, as well as our in-depth knowledge of local
building needs, to develop innovations that help makeyou more successful and drive sustainable construction.
The comprehensive portfolio under the Master Builders
Solutions brand encompasses concrete admixtures,cement additives, chemical solutions for undergroundconstruction, waterproofing solutions, sealants, concrete
repair & protection solutions, performance grouts, andperformance flooring solutions.

3

TBM
from Master Builders Solutions

Specialty Chemicals for Safeand Efficient TBM Tunneling
Mechanized tunneling is the safest and quickest way oftunneling especially under difficult geological conditions andin urban areas. The optimum TBM (Tunnel Boring Machine)
performance is achieved by combining both mechanical andchemical engineering.

Soil Conditioners

Annulus Grouts & Concrete Segments

Anti-Wear & Anti-Dust

Injection, Stations, Cross Passages &Cutterhead Intervention

EPB (Earth Pressure Balance) tunnelingrequires the correct use of soil conditioners to
reduce cutterhead torque and tool abrasion andincrease advance rates. A selection of leading
technology foams, polymers and anti-clay
agents provide the solution for every geologicalsituation.
Hard rock TBMs as well as soft ground TBMs
may experience excessive wear and hightemperatures of the cutting tools. Newly
developed anti-wear agents ensure a longer
cutter life and a dust-free working environment,
especially for hard rock TBMs.

Tail Sealants

The TBM tail shield needs to be sealed against
water, soil and annulus grout ingress. Tailsealants have been developed to ensure
reliable sealing together with the brush system– the largest TBM diameter being 17.6 meters to
date.

Main Bearing Greases

Every main bearing needs to be protected andlubricated as this is the costliest part of the
TBM. Sealing and lubrication greases are alsoavailable in a renewable raw material version,leading the industry towards the highest
environmental standards.

Safe and reliable annulus grout applications
require a specific selection of accelerators,
retarders and stabilizers. High early strength
development is of key importance for concretesegment manufacturing. A wide range ofconcrete admixtures is available for bothtechnologies.

To strengthen geological fault zones andprevent water ingress, a comprehensive range
of injection products is available, especiallysuited to pre-injection. Sprayable membranes
enable a cost-efficient composite shell lining forcross passages, access and escape routes andutility caverns. They can also be used for
cutterhead interventions, providing an effective
barrier against compressed air loss.

5

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TBM
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Soil Conditioners
Earth Pressure Balance (EPB) tunnel boring machinesrequire the use of soil conditioners which must be adapted
to the geology to ensure the safe advance and maximum
efficiency of the TBM. Of increasing importance are thecost-effective soil disposal and even the re-use of the
excavated material. The Master Builders Solutions teamoffers competent service and expert support backed up by
local lab facilities.

1.

2.

1. Foams – MasterRoc SLF 30, 32, 34, 41, 47, 50, andrecent introductions 325, 419, and 543
Torque and wear reduction are the key to achieving safeand economical TBM tunneling. MasterRoc SLF foams
ensure maximum performance and can be adapted to thegeology encountered.
2. A
 nti-Clay Additives – MasterRoc ACP 127, 147,
143, 211, and 214
MasterRoc ACP anti clay additives are the worldwide
leading technology for powerful and cost-efficient EPB
tunneling in clayey soils. The portfolio includes pure anticlay additives or formulated products based on foams andpolymers. Master Builders Solutions ensures a continuous
development of this innovative technology.

3.

4.

3. Polymers – MasterRoc SLP 1, SWA 710, and 750
Stabilizing polymers are used to combat high watercontent or pressure, instable ground conditions andsharply graded soils. These unique polymers have a low
impact on the environment, and they can be used throughthe foaming system or injected by separate lines in thechamber or screw.
4. Laboratory testing & expert support
Safe and efficient tunneling already starts at the planningstage. Detailed laboratory tests of soil from the project
location prior to excavation are essential. Based on theselaboratory tests, the contractor is able to judge the use of
the best suitable product and it provides him with thenecessary information for the setup of the foam
parameters on the TBM.

TBM
from Master Builders Solutions

7

Challenging Project Solutions

1.

2.

1. Galleria Sparvo, Italy
An EPB TBM with a cutterhead diameter of 15.55 m
advanced through clay, claystone and sandstone geology
which partly contained gas. The key success factor for thesoil conditioning was the efficient reduction of torque evenunder mixed face conditions and EPB pressure of up to
3.5 bar using MasterRoc SLF 41 and MasterRoc ACP
143.
2. A
 laskan Way Viaduct Replacement Tunnel,
Seattle/WA (USA)One of the world’s largest EPB TBM (Ø 17.5 m) was
utilized to construct a double deck road tunnel underneaththe city of Seattle. The majority of the alignment consistedof cohesion less, poorly graded sand and gravel withstretches of cohesive clay and silt. Both conditions werechallenging especially due to the large diameter andrequired exceptional performance of the soil conditioning
products. The extremely high half-life of the MasterRoc
SLF 50 maintained consistent characteristics of the treatedbsoil throughout the excavation chamber and screw

3.

4.

conveyor. The MasterRoc ACP 147 was successfully
utilized to manage the cohesive clay sections.
3. Toronto Metro Extension, Canada
A total of 4 TBMs were launched, with MasterRoc SLF 47
and MasterRoc ACP 127 and 211 being the key factor for
success in difficult high clogging clay conditions. The
TBMs advanced over 80 mm/min, achieving highproduction levels of more than 30 m/day steady advance.
The cutterhead torque was maintained well under the
installed level, reducing energy consumption considerably.
The EPB pressure reached 2-2.5 bar, and very low to nosettlement was recorded.
4. Delhi Metro Extension, India
Numerous TBMs from various machine manufacturers(Robbins, Herrenknecht, Terratec) were working for theDelhi Metro project in sand to stiff clay geology. MasterRoc
SLF 30 and 41 ensured a quick and steady advance withminimum surface settlements. MasterRoc ACP 143 wasused when sticky clay was encountered.

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TBM
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Anti-Wear & Anti-Dust
In hard rock tunneling as well as soft ground tunneling, theTBM often experiences excessive wear. The Master Builders
Solutions team was one of the first to specially develop new
solutions against wear and dust on tunnel boring machines. It
is of great importance to identify these project challenges as
early as possible to implement efficient counter measures toreduce the wear at the cutterhead and at the screw conveyor
level. To apply the MasterRoc ABR additives in the mostefficient way, a semi-automatic foam system is needed,
specially designed for use on hard rock TBMs.

1.

2.

1. Anti-wear and anti-dust – MasterRoc ABR 5 /Anti-dust – MasterRoc ABR 2 and 7
Tunneling efficiency is improved by protecting the steel
tools, reducing cutter blocking and tool temperature duringboring. Current site results show a wear reduction ofroughly 25% and a dust free working environment for the
personnel.
2. Anti-clogging – MasterRoc ABR 5 and 7
The water sprinkler system typically used to decrease thecutter temperatures and the dust level often leads toclogging of the fine soil particles and blocking of thecutters. MasterRoc ABR prevents the fine particles fromclogging and keeps all steel surfaces clean.

3.
3. Wear prediction
Until the development of the Soft Ground Abrasion Tester(SGAT) device, wear prediction of compacted soft grounds
was not possible. Now, the effects of varying moisture
contents of the soil, the use of anti-wear agents as well as
soil conditioners can be studied in detail. These results areused to optimize TBM performance on site.

TBM
from Master Builders Solutions

9

Challenging Project Solutions

1.

2.

1. Westerly Tunnel – Cleveland, Ohio, USA
The Westely Tunnel is a sewer tunnel part of the Project
Clean Lake, is using a Lovsuns Single Shield TBM in its
way through the Chagrin Shale. The Chagrin shale consistof siltstone, silty gray shale and soft gray clay shale. The
Chagrin Shale is classified as a weak to medium-strongrock, with a compressive strength from 34 Mpa to 100
Mpa. ABR 7 is mainly used as a dust suppressant.
2. Faroe Islands, Denmark
One Robbins main beam hard rock TBM was used in the
Faroe Islands for the Eidi water transfer project in granite
formations. MasterRoc ABR 5 was predominantly used toreduce the dust level inside the tunnel to improve theworking conditions.

3.

4.

3. AMR, India
The AMR water transfer project in India used two shielded
hard rock TBMs in hard and abrasive granite reachingstrengths of 100-275 MPa with a quartz content ranging
from 35-70%. This resulted in a very low Cutter Life Index(CLI) of 3.8-5.5. MasterRoc ABR 5 was used to reduce thewear, tool temperature and dust level.
4. Sochi, Russia
Several TBMs were used for the 2014 Sochi WinterGames transportation scheme. High tool wear was
experienced, and where water ingress occurred, thecrushed rock paste plugged the cutter housing, blocking
the disk. MasterRoc ABR 5 was used to reduce the tool
wear and clogging effect. The geology consisted mainly of
hard fractured limestone and porphyry with difficult fault
zones.

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TBM
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Tail Sealants

Reliable and cost-efficient sealing of the TBM tail shieldis essential for a smooth tunneling operation. Regardlessof the soil conditions and the annulus grout type used, theMasterRoc TSG tail sealants effectively prevent not only
water but also soil and annulus grout from entering the TBM.
Master Builders Solutions offers an inert tail sealant that
does not produce any negative side effects for the concreteand the EPDM gaskets.

TBM
from Master Builders Solutions

1.

2.

1. Driving grades – MasterRoc TSG 6 and 800
Both products have excellent adhesion to metal andconcrete surfaces, even under water. To seal the complete
circumference of the shield, the driving grade must flow
well between the injection points. The consumption ofMasterRoc TSG depends on numerous factors such as theroughness of the concrete segment, tunnel lay out andcondition of the brushes, normally reaching 0.8-1.2 kg/m2
of the segment surface.
2. First fill grade – MasterRoc TSG 7 and 870
The specially designed first fill sealant is of significant
importance: once applied into the newly installed brushes,
it protects them by preventing the penetration of water, soil

113.
and annulus grout. Additionally, it ensures the flexibility ofthe brushes which is necessary to follow the movementsof the tail shield.
3. Product design and performance
MasterRoc TSG is made from high-molecular polymers,
natural fillers and fibers. Important typical properties
are a water spray off (ASTM D 4049) and a sealing
capacity above 34 bar (Matsumura sealing test).
MasterRoc TSG 800 and TSG 870 are fire resistantgiving optimum safety during tunnel excavation.
MasterRoc TSG has been successfully used worldwide
on Herrenknecht, Robbins, Lovat/Cat, Hitachi, Mitsubishi
and Kawasaki.

Challenging Project Solutions

1.

2.

3.

4.

1. Galleria Sparvo, Italy
An EPB TBM with a cutterhead diameter of 15.55 m
advanced through clay, claystone and sandstone geology
which partly contained gas. The 2-component annulus
grout reached the 4.5 bar maximum pressure. MasterRoc
TSG 6 and 7 sealed the TBM successfully through its
2500 m long advance.

3. Saverne, France
The convertible TBM used the TSG 6 driving grade during
both the EPB and hard rock modes. Consumption values
reached around 1.2 kg/m2 of segment surface during EPB
mode and around 0.5 kg/m2 during hard rock mode. The
TSG 7 first fill grease ensured brush protection during the3800 m advance.

2. Toronto Metro Extension, Canada
Several EPB TBMs used the MasterRoc TSG 6 driving
grade as well as the TSG 7 first fill grade during theiradvance in Toronto. The 2-component annulus groutpressure reached 4.5 bar. A special challenge was thevery low temperatures at the start shaft.

4. Moscow metro, Russia
The fire resistant MasterRoc TSG 800 was used in the
new metro ring line in Moscow. The 6.25m diameter TBM
excavated in clay conditions and the MasterRoc TSG800
sealed the TBM effectively against any ingress from wateror grout.

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TBM
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Main Bearing Greases
The costliest part of the TBM is the main bearing, which
therefore has to be well maintained. For this reason,
Master Builders Solutions ensures highest raw material andproduction quality by only producing the greases at a few wellselected sites around the world. All MasterRoc EPB and BSG
greases have Merkel certification. Apart from the standard
greases (EPB/BSG 11), highly biodegradable greases madefrom renewable raw materials (EPB/BSG 1) have beendeveloped.

1.

2.

1. Protection of the main bearing
Generally, there are two different types of greases used
together: main bearing lubricants (EP greases) and main
bearing sealants. The main bearing sealants have astronger adhesion to metal surfaces and higher wash-off
resistance than EP greases, but less lubrication
properties. The consumption level of both greases
depends on the recommendation of the TBM suppliers.
2. Main bearing lubrication – MasterRoc EPB 1 and 11
The lubricants based on synthetic or vegetable oil containantioxidants, corrosion inhibitors and EP/AW additives.
They offer excellent mechanical stability, load carrying
capacity and corrosion protection, which makes themsuitable for heavy loaded bearings as well as wet
environments. Important typical properties are a 4-ballwear (DIN 51350:5) of around 0.5 mm and a water sprayoff (ASTM D 4049 @ 25°C) of below 15%.

3.
3. Main bearing sealing – MasterRoc BSG 1 and 11
The sealants are excluder greases that effectively protect
the main bearing by preventing water and soil
from entering into the sealing system. They are formulated
based on synthetic or vegetable oil to resist high waterand ground pressure and have good lubrication andpumping properties with excellent adhesion to all surfaces.
Important typical properties are a 4-ball wear
(DIN 51350:5) of below 0.9 mm and a water spray off(ASTM D 4049 @ 25°C) of roughly 3%.

TBM
from Master Builders Solutions

13

Challenging Project Solutions

1.

2.

1. Moscow Metro Extension, Russia
MasterRoc BSG 11 was used in combination withMasterRoc EPB 11 on 8 EPB TBMs to date, manufactured
by CAT, NFM and Robbins. The EPB pressure reached
1-3 bar with high ground water flow, reaching at up to
20 m3/h at some sections.
2. Toronto Metro Extension, Canada
Several EPB TBMs in Toronto used the MasterRoc BSG 1
main bearing sealing grease. It was chosen due to its
renewable raw material content. A special challenge wasthe very low temperatures at the start shaft.

3.

4.

3. Sochi, Russia
MasterRoc EPB 11 was used on 3 TBMs: 6 m Lovat EPB
TBM at Tunnel 3 North (pressures reached 0.8-4.0 bar), 6m Lovat/Selli double shield hard rock TBM at Tunnel 3South and 10 m Lovat hard rock TBM at Tunnel 3 South.
4. Istanbul Metro, Turkey
Several EPB TBMs used the MasterRoc BSG 1 main
bearing sealing grease for the entire project. The EPB
pressures reached 1-4 bar.

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TBM
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Annulus Grouts & Concrete
Segments
When the segmental lining is installed inside the TBM,
the space between the ground and the segments – theannulus gap – must be filled in an efficient and reliable way
to prevent settlements. In most cases, this space is filled bya cementitious grout, for which Master Builders Solutions
provides a full range of admixtures.
Concrete quality is a very important aspect for segment
production, especially as tunnels today have a designed
lifetime requirement of 100 years. High performing concrete
additives are necessary to ensure not only durability but also
efficient production.

1.

2.

1. Annulus grout additives
The main goal of annulus grouts is to minimize surface
settlements. Furthermore, the annulus grout protects boththe outside surface of the segments and the EPDM
gaskets and finally supports the segments to prevent
floating. The use of retarders, accelerators,
superplasticizers or air entrainers ensures a reliable andeasy to handle grout formulation.
2. Shield stabilization and lubrication
In projects with a big TBM diameter or very unstableground conditions, shield stabilization grout can reducesurface settlement and prevent the shield from becoming
blocked. For this application the use of polymerized
bentonite or sand suspensions is ideal. MasterRoc SLP
Polymers can also be used for clay swelling inhibition andto lubricate the shield3.

3. Segment concrete
MasterGlenium superplasticizers and MasterFinish form
release agents reduce the curing time of the concrete andallow earlier demolding, leading to shorter production
cycles. This reduces energy consumption while increasing
productivity and improving work safety. Furthermore, thedurability of the concrete itself is enhanced.

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17

Injection

1.

1. Pre-injection
Pre-injecting the ground is an important measure tostabilize fractured rock and to prevent water ingress,
especially in geological fault zones. It is essential that the
TBM already has all the necessary equipment installedprior to commencing the tunneling operation, as retrofitting
is costly, time consuming and quite often only partiallypossible. This includes drilling and mixing equipment aswell as the drill jigs which go through theshield, and, if necessary, through the cutterhead. Master
Builders Solutions offers microcements and colloidal silica
to penetrate low permeable ground. The most economical
and technically suitable product can be provided for eachgeological situation. This proven concept also fulfills
environmental standards for drinking water, which was forexample required by the Arrowhead project in the USA.

2.

2. Post-injection
Post-injection on a TBM can be used for void filling, water
stopping and concrete repair. The polyurea silicate
MasterRoc MP 367 Foam is excellent for void filling (lessadhesion to the metal TBM parts), the polyurethane
MasterRoc MP 355 for water stopping, and the acrylic
resin MasterRoc MP 307 CE for concrete repair.
More details are available in the Master Builders Solutions
Injection brochure.

Mastering underground construction challenges requires the rightpartner. Continuous innovation and customized solutions ensurethat customers using Master Builders Solutions operate successfully,
and to the highest safety standards.

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TBM
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Stations & Cross Passages

Stations and Cross Passages

Master Builders Solutions offers a unique solution with its
MasterSeal 345 sprayable waterproofing membrane,
allowing design flexibility for difficult geometries such as
tunnel intersections, and also for station and accesstunnels and cross passages. When placed in a sandwich
structure between two sprayed concrete layers,
MasterSeal 345 also offers design optimization, creatinga double bonded composite shell lining. Special
design guidelines are available to support all projects.
Selected references are the Singapore and Sofia Metroprojects.

TBM
from Master Builders Solutions

19

Know-how and Service

Training and Education

The Master Builders Solutions brand brings all of ourexpertise together to create chemical solutions for new
construction, maintenance, repair and renovation of
structures. Master Builders Solutions is built on theexperience gained from more than a century in theconstruction industry.
The know-how and experience of a global community of
construction experts form the core of Master Builders
Solutions. We combine the right elements from ourportfolio to solve your specific construction challenges. We

collaborate across areas of expertise and regions anddraw on the experience gained from countlessconstruction projects worldwide. We leverage global
technologies, as well as our in-depth knowledge of local
building needs, to develop innovations that help make you
more successful and drive sustainable construction The
comprehensive portfolio under the Master Builders
Solutions brand encompasses concrete admixtures,cement additives, solutions for underground construction,waterproofing solutions, sealants, concrete repair &protection solutions, performance grouts, and performanceflooring solutions.

More brochures on our underground construction solutions are available athttps://ugc.master-builders-solutions.com.
Documentation available on request:n Reference list
n Project reports
n Technical data sheetsn Design guidelinesn Method statements

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Complete solutions for air
entrained concrete

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Solutions for precision grouting
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Comprehensive solutions for fiber
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Solutions for concrete
strengthening

MasterGlenium
Solutions for high performance
concrete

MasterCast
Solutions for the manufactured
concrete product industry
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Solutions for cement manufacture
MasterEase
Low viscosity for high performance
concrete
MasterEmaco
Solutions for concrete repair
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Solutions for formwork treatment
and surface improvement

		

MasterInject
Solutions for concrete injection
MasterKure
Solutions for concrete curing
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Solutions for enhanced
durability
MasterMatrix
Advanced rheology control for
concrete

MasterPel
Solutions for hydrophobization,
anti-efflorescence andsurface protection
MasterPolyheed
Solutions for mid-range concrete
MasterPozzolith
Solutions for water-reduced
concrete

MasterSet
Solutions for set control
MasterSphere
Solutions for guaranteed
freeze-thaw resistance
MasterSuna
Solutions for sand and gravelin concrete

MasterProtect
Solutions for concrete protection

MasterSure
Solutions for extraordinary
workability retention

MasterRheobuild
Solutions for high strength
concrete

MasterTop
Solutions for industrial andcommercial floors

MasterRoc
Solutions for undergroundconstruction

Master X-Seed
Advanced accelerator solutions
for concrete

MasterSeal
Solutions for waterproofing
and sealing

UcreteFlooring solutions for harshenvironments

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Master Builders Solutions
Deutschland GmbH
Salzachstr. 17
68199 Mannheim, Germany
ugc@mbcc-group.com

Master Builders Solutions
Admixture Systems US, LLC
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Beachwood, OH 44122, USA
P +1-216-839-7500
admixtures@mbcc-group.com

Master Builders Solutions
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de Químicos para
Construção Ltda.
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Pinheirinho,
Vila Prudente
03210-001, Sao Paulo, Brazil
P +55 (11) 3164-4277
sac.eb@mail.mbcc-group.com

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Pte. Ltd.
1 Harbourfront Avenue #07-07/08
Keppel Bay Tower
Singapore, 098632
P +65 6232 4888

Master Builders Solutions
Construction Chemicals LLC
Head Office: Dubai Investments
Park,
PO Box 37127
Dubai
United Arab Emirates
P +971 4 8090800
ugc@mbcc-group.com

The data contained in this publication are based on our current knowledge and experience. They do not constitute the agreed contractual quality of the product and, in view of the many factorsthat may affect processing and application of our products, do not relieve processors from carrying out their own investigations and tests. The agreed contractual quality of the product at the timeof transfer of risk is based solely on the data in the specification data sheet. Any descriptions, drawings, photographs, data, proportions, weights, etc. given in this publication may change without
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