HBS Backfill Grouting system

The Häny HBS backfill grouting system is developed especially for the grouting of segmental liners behind mechanised TBM tunnelling. The system is designed for pressure controlled grouting for filling the entire annulus, or for quantity controlled grouting of the invert segments only.

Control functionsControl by pressure

The injection pressure is continuously measured by

means of transducers mounted in or close to the tail

shield injection pipe of the TBM. A PLC with touch screen

panel monitors and controls the pre-set pressure range

for that specific line. If pressure reaches the pre-set max-

imum the pump automatically stops, to start again auto-

matically when pressure hits the lower limit.

Once each pump is activated, plc control function is fully

automatic. If the pressure at the injection point fails to

increase to the required pressure within an adjustable

time limit after start of pumping, an alarm triggers imme-

diate attention by the operator.

Control by quantity

In cases where only the invert is to be grouted, the desired

quantity of grout can be pre-set. Whenever this quantity

is reached, the pump will automatically be stopped. If an

accelerator is added to the grout mix, the dosing pumps

can be switched off earlier to avoid setting of the mortar in

the grout lines.

The entire backfill process is controlled from a touch screen

panel, placed either in the main TBM control room or at

the main control cabinet. A window, showing the schematic

of the tail shield allows the TBM or grouting operator to

start and stop the grout pumps.

It also shows the pressure at the tail shield grout pipes; the

pressure at the pumps; the pumping rate and total quantity

pumped by each pump; as well as the accumulated injection

values for all pumps.

Quantities are measured by either counting the pump

strokes or recorded by inductive flow meters and are dis-

played in a control screen window that also indicates the

The Häny HBS backfill grouting system always uses one

grout pump for each point of injection. It can be adapted

for either mixing pre-blended dry mortar, or for using

ready-mixed mortar.

This highly flexible system is based on standard pump

components and various control options to allow different

degrees of automation.

Mixer

Agitator car

Pumps

Pressure

Transducers

Agitator

Main control

Touch panel

(TBM Control room)

P4

P1

P2

P3

P4

P2

P1

P3

values for the last 20 shoves and the total quantity of

grout pumped since the start of the project.

The volume per stroke, start and stop pressures, delays

for alarms, and other operating data are displayed and set

in a separate window. After each shove, the total quantity

per shove can be re-set.

The main control comprises a plc and all the high voltage

components necessary for the operation of the grout

pumps. For maintenance and cleaning, a switch allows

direct control of the pump at the grout station while a

safety switch prevents unauthorised or accidental opera-

tion of the system from a remote control panel.

Maximum pressure and maximum output of each pump

can be manually pre-set at the pump. Through this func-

tion, the maximum pressure in the system can be limited

and the output of the pump can be adapted to the advance

rate of the TBM. The fine control is affected through the

pressure- and quantity-dependent plc control.

Integral system

By complimenting the HBS with a Häny HCM series high-

shear mixer, several other operations are possible. Ben-

tonite, for example, can be mixed in place to clean out the

grout lines for longer periods of downtime. The same equip-

ment can also be used if pre-excavation grouting is required

to stabilise bad ground conditions. Cement or ultra fine

cement is mixed efficiently in the HCM mixer and injected

by the same pumps normally used for backfilling. Since

backfilling and pre-grouting processes are never needed

or executed at the same time, this dual-purpose applica-

tion is importantly cost efficient, saves considerable space

on the TBM back-up gantries, and reduces the inventory of

equipment that needs to be managed and maintained by

the tunnelling crews.

Pump and alarm settings.

Space saving, vertical arrangement of the pump.

Recording of quantity.

Häny AG • Buechstrasse 20 • CH-8645 Jona/SwitzerlandTel. +41 44 925 41 11 • Fax +41 44 923 62 45 • info@haeny.com • www.haeny.com

1) Grouting of invert with

continuous mixer for

pre-blended dry mortar.

Bözberg Highway Tunnel,

Switzerland.

2) TBM control room

with touch screen control

panel for segmental lining

backfilling. Guadarrama

High Speed Rail Tunnel.

North Portal, Spain.

3) Grouting of invert with

continuous mixer for

pre-blended dry mortar.

Guadarrama High Speed

Rail Tunnel. South Portal,

Spain.

4) Pumps for backfilling

of the tunnel lining arch

section with ready mixed

grout. Guadarrama High

Speed Rail Tunnel.

North Portal, Spain.

5) Grouting with

continuous mixer for

pre-blended dry mortar

Abdalajis High Speed Rail

Tunnel. Malaga, Spain.

6) Pumps for backfilling

of the entire segmental

lining annulus with ready

mixed grout.

Channel Tunnel Rail Link

(CTRL) Contract 240.

London UK.Häny AG reserves the right to make improvements and modifications to their equipment without notice.

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