Eppenberg tunnel: Hydroshield TBM drive in highly permeable soils above the groundwater table – Unexpected problems and their solution.

As part of the four‐track improvement of the Zurich‐Berne line near Aarau, the 3.1 km long Eppenberg Tunnel was bored using a multi‐mode TBM. This involved driving more than 700 m in highly permeable soils, mostly above the groundwater table. The hydroshield drive was confronted with considerable problems. The static yield point of the bentonite slurry repeatedly fell below the critical limit of 10 N/m2, despite its frequent replacement. As a result, large quantities of slurry penetrated into the ground and large quantities had to be replaced. In addition, significant additional grout quantities were repeatedly observed for the filling of the annular gap. A systematic and analytical approach in cooperation with all parties involved made it possible to determine the behaviour of the system. Problems started with highly permeable open‐framework gravel layers, which permitted the slurry to penetrate far into the ground. This resulted in overbreak in the crown and local underpressure of the slurry with respect to the grout around the shield. Consequently, the annular gap grout flowed past the shield tail seal and destroyed the thixotropic properties of the slurry by adding free Ca cations. The slurry became unusable and had to be replaced. An extensive set of measures finally made it possible to solve the problems and safely bring the excavation to breakthrough. [ABSTRACT FROM AUTHOR]