MICROTUNNELING

Method of Operation
 METHOD OF OPERATION - MICROTUNNELING

MICROTUNNELING SYSTEM OVERVIEW

Slurry microtunneling is a trenchless underground

construction method employed to accurately
install pipelines under existing utilities, highways,
railroads, levees, waterways, in sensitive wetlands,
unstable ground conditions, and contaminated
soils. Microtunnel Boring Machines (MTBMs) install
pipelines from shaft-to-shaft or can be retrieved from
a body of water.

Microtunneling is desirable for its ability to reduce

project risk, constrain the construction zone within Figure 1. Microtunneling systems are remotely controlled from a control
easements and right of ways, minimize ground console inside the control container on the surface.

surface settlement, and is applicable to a wide range

of geological and changing ground conditions with MICROTUNNEL BORING MACHINES (MTBMS)
extreme accuracy.
Akkerman MTBMs are manufactured in base sizes of
Microtunneling systems are remotely-controlled and 30-114-inches OD, and are available in center drive
comprise several pieces of machinery or subsystems models for smaller base diameter machines, and
that function together. They are managed by an face-access, peripheral drive models for the largest
operator who monitors and controls pipe jacking diameters. Center drive MTBMs contain a single
operations from a console inside a container on motor that drives a planetary gear box, coupled to a
the surface, alongside the launch shaft (see Figure drive shaft in the center of the MTBM (see Figure 2).
1). Personnel entry in the tunnel is not required for Face-access, periphery drive MTBMs have interior
routine operation of a microtunneling system. motors on the periphery of the gear ring with pinions
on a slewing bearing (see Figure 3).
MTBMs are accurately controlled by exerting
continued support at the face of the bore
by balancing thrust pressure and slurry with
groundwater and earth pressures. This support at
the face differentiates it from other open-face pipe
jacking and tunneling methods.

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 PLANETARY GEARBOX

ELECTRIC MOTOR

Figure 2. Center drive MTBM contains a single motor that drives a planetary gearbox coupled to a drive shaft.

PINIONS AND MAIN DRIVE HYDRAULIC

SLEWING BEARING MOTOR AND GEARBOX (4)

Figure 3. Face access periphery drive MTBMs contain four interior motors on the periphery of the gear ring with pinions on a slewing bearing
(some components removed for visibility).

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 METHOD OF OPERATION - MICROTUNNELING

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Face-access, periphery drive MTBMs feature
higher power and torque for the larger diameter
pipe installations, and an access door at the cutter 1
head with back loaded tooling mounts (see Figure
4) to replace worn tooling on extended drives.
These MTBMs come with an on-board electric over
hydraulic power pack for cutter head drive in low, 1
medium, and high torque for accurate control in
changeable geology.

Figure 5. MTBM crushing cone 1) high pressure jetting nozzles, 2) slurry inlets,
and 3) slurry cutting nozzles.

MTBM cutter heads are configured as follows

(see Figure 6):

• Soft ground - carbide tipped bullet and

chisel teeth
• Mixed ground – a mixture of carbide tipped
Figure 4. Photo of the periphery drive MTBM access door with back loaded bullet, chisel teeth and disc cutters
tooling mounts.
• Rock - disc cutters
• Project specific cutter head – includes a
All Akkerman MTBMs feature high pressure jetting combination of all the above tooling
nozzles (see Figure 5) that speed up the breakdown
of the cuttings and cleans the crushing cone to Cutter head outer gauge cutters overcut typically
prevent clogging in the slurry intake manifold. The up to one inch in radius larger than the pipe OD
articulated steering joint extends and retracts with to reduce friction on the pipe string as it is jacked
three-point steering control. Hydraulically activated through the ground.
dirt wings on the outside of the MTBM minimize
MTBM torque roll. Akkerman MTBMs include a Cutter heads can be equipped with increase kits for
live one or two-way audio and camera systems adaptability. Cutter head and crushing cones are
for system monitoring for maintenance and target hard-faced to withstand wear.
viewing.

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 SOFT GROUND MIXED GROUND ROCK
CUTTER HEAD CUTTER HEAD CUTTER HEAD
For soft, wet, easily displaceable ground For varying, soft to high compressive For high compressive strength geology
Bullet Bit Tooling strength geology Disc Cutters and Bucket Scrappers
Disc Cutters and Bullet Bit Tooling

Figure 6: Standard Microtunneling Boring Machine cutter head configurations.

CONTROL CONTAINERS The remote hydraulic power pack is situated

alongside the control container on the project
The control container features a climate-controlled site to supply hydraulic distribution to the jacking
operator’s area and a separate power distribution frame, auxiliary functions and intermediate jacking
area. Operators monitor and adjust all facets stations/propulsion cans if relevant.
of the microtunneling operation from a multiple
monitor display console including MTBM’s pitch,
yaw, rotation, torque, jetting, jacking thrust advance
rate, ground pressure against the face, slurry flow
and pressures, the MTBM’s anticipated position
at the cutter head face, and air and drive motor
temperatures all using proprietary software (see
Figure 7). The system logs over 100 data points for
customized reporting to track and graph alignment
deviation, face pressure and torque changes. An on-
site generator or 480 vac 3 pti line power supplies
electricity for the control container.

Figure 7. Microtunneling control console screen displaying functions of the

MTBM using the Akkerman proprietary software.

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 METHOD OF OPERATION - MICROTUNNELING

SOIL DIGESTION AND SLURRY CIRCULATION rates using sensors, flow meters and pit valves in the
closed loop slurry system. Balancing the input and
The MTBM excavates spoil at the face of the bore output of the slurry by volume and pressure is vital
while simultaneous pipe segments are installed in for effective and accurate advancement and to avoid
the launch shaft and thrust forward by the hydraulic overloading the cutter head or removing too much
cylinders on the jacking frame. The MTBM’s rotating soil thereby causing settlement.
cutter head is steerable, and bi-directional for
precise ground excavation.

The forward advancement of the pipeline combined

with the rotating action of the cutter head excavates
the soil and forces the cuttings into the cutter head’s
crushing cone and pulverizes them into smaller
particles for transport through the slurry lines.
MTBMs are capable of crushing cobbles up to 28%
of its outside diameter.

Slurry is formed by mixing the ground-up cuttings

with water by injecting water or a water with a
Figure 7. Cuttings are pulverized into smaller particles in the crushing cone
bentonite clay mix in the MTBM’s crushing cone. then forced for transport through the slurry lines.
Inside the crusher cone, cobbles breakdown, are
mixed with slurry and pass through the slurry inlet
holes for transport into the slurry return lines (see
Figure 7).

Feed, return and booster pumps keep the slurry

traveling to a slurry separation tank, slurry tank
or settlement pond where it is separated and re-
circulated back to the cutter head in a closed system
(see Figure 8). The slurry balance system is deployed
immediately at launch to prevent material from
entering the MTBM’s inner chamber.

Operators carefully monitor the face pressure by

simultaneously assessing a combination of spoil, Figure 8. Slurry travels to a separation tank and is re-circulated back to the
groundwater volume, and slurry feed and return flow cutter head in a closed system.

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PREPARING THE SHAFTS

A contractor must design and construct the jacking

and if applicable, receiving shafts. It is important
that the jacking frame tonnage and jacking pipe
loads are properly calculated during the design.

A concrete reaction wall is poured at the rear of the

jacking shaft to disperse jacking loads (see Figure
9). The jacking force is bore by the jacking frame
against the reaction wall, shaft wall and ground Figure 9. Concrete reaction wall is poured at the rear of the jacking shaft to
disperse jacking loads.
outside of the shaft.

In order to stabilize the soil around the shaft, ground

improvement and/or dewatering takes place.

The MTBM is typically launched through a shaft

seal on the launch shaft wall which acts as a gasket
around the pipe to prevent subsidence from entering
the launch shaft (see Figure 10).

The reception shaft or exit shaft is often prepared Figure 10. The MTBM is typically launched through a shaft seal to prevent
with a retrieval shaft seal mounted on the shaft wall subsidence from entering the launch shaft.
at the anticipated MTBM emergence location.

After it emerges, all slurry, ventilation,

microtunneling utility and electrical lines are
removed from the reception shaft.

If the project design requires an MTBM wet retrieval,

the back of the MTBM is equipped with a bulkhead
to create a water tight seal between the body of
water and the tunnel and shaft. Crews will enter
the tunnel from the launch shaft end, disconnect
and remove the microtunneling utility lines from the
reception shaft. After it’s disconnected from the Figure 11. MTBM emerging from a wet retrieval after the bulkhead seals
tunnel, the MTBM is advanced forward into the body off the tunnel.

of water for retrieval by divers (see Figure 11).

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 METHOD OF OPERATION - MICROTUNNELING

JACKING FRAMES

The jacking frame is sized to accommodate the

MBTM, pipe diameter and the specific needs of the
project according to ground conditions and shaft
length.

The jacking frame is positioned in front of the

reaction wall on line and grade (see Figure 12).
During setup, a stationary set of cables is routed
from the bulkhead connection on the control
container to the jacking frame in the launch shaft.
Figure 12. The jacking frame is positioned in the base of the launch shaft on
The jacking frame contains horizontally-mounted line and grade and its hydraulic cylinders advance the MTBM and pipe.
hydraulic cylinders that advance the MTBM forward
with up to 1,200 tons of thrust. Keyed notches on
the cylinders lock into place to ensure smooth and
continuous advancement.

To advance the MTBM and pipe string and add new

pipe segments, the jacking frame exerts uniform
hydraulic jacking force onto a thrust ring which
moves the MTBM and then previously installed pipe
along the path of the alignment. The force of the
jacking frame reacts against the concrete thrust
block and the ground outside of the shaft. Between
the installation of each pipe joint, MTBM rotation
and slurry flow is paused, the jacking frame’s
hydraulic cylinders are retracted with a winch, a
new pipe joint is lowered onto the jacking frame,
microtunneling utility lines are added and connected
to the existing lines, and mining is resumed (see Figure 13. As pipe segments are lowered into the launch shaft, microtunneling
utility lines are lowered inside the pipe and are connected to the existing lines.
Figure 13).

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PUMPS
A slurry booster pump is often placed within the
Slurry is circulated through the microtunneling MTBM to aid in transporting the heavy, soil-laden
lines with feed, return and booster pumps that are slurry from the MTBM to the launch shaft.
regulated through the control container’s variable
frequency drives. A high-pressure jetting pump provides high velocity
jetting through the microtunneling utility lines to the
The slurry feed pump is located on the surface near MTBM cutter face to break down clay and silty soil,
the slurry tanks, settlement ponds or separation clean the crushing chamber and assist with spoil
plant. The slurry feed pump pushes the slurry water intake and flow.
to the MTBM for slurry injection in the crushing
chamber.

The slurry return pump is placed in the bottom of the

MTBM launch shaft to assist with the flow of the soil-
laden slurry back up to the surface for separation,
then is re-circulated through the system.
REMOTE
HYDRAULIC
POWER PACK CONTROL CONTAINER

WATER COOLING HIGH PRESSURE

BENTONITE & TANK JETTING PUMP
LUBRICATION
PUMP
FLOW
METER

SLURRY
FEED PUMP

SLURRY
ACTIVE SLURRY
BOOSTER
TARGET RETURN
PUMP
PUMP ACTIVE
GUIDANCE
SYSTEM

ACTIVE
TARGET JACKING FRAME
Figure 13. The jacking frame is positioned in the base of the launch shaft on line and grade and its hydraulic cylinders advance the MTBM and pipe.

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 METHOD OF OPERATION - MICROTUNNELING

WATER COOLING TANK projects presenting varying ground conditions,

contains larger valves that feed the MTBM’s
The water-cooling tank, positioned alongside the lubrication ports for bentonite injection around
launch shaft, provides cool water which travels the pipe annulus (see Figure 14)
through utility lines to keep the MTBM’s drive motor
and in some applications, the booster pump motor • Pipe Clamp – to contend with buoyant forces
cool, and flush seals for optimal operation (see when installing a MTBM within a body of water,
Figure 13, previous page). This cool water flow also the pipe clamp holds the previously installed
assists to cool the tunnel air temperature which pipe in place while the next pipe joint is being
helps with the guidance system’s laser clarity. installed (see Figure 15)

ANCILLARY EQUIPMENT • Automatic Bentonite Injection System –

Remotely-controlled, delivers lubricant directly
For specific project conditions, the following ancillary to the annulus of the pipe at predetermined
equipment is sometimes used on a microtunneling pressures and intervals to reduce jacking forces
project, although the list is not exhaustive: (see Figure 16)
• Sealed Intermediate Jacking Stations – • Compressed Airlock Package – a decompression
distribute thrust load to facilitate longer drives chamber that allows manned entry to the MTBM
face on projects located under groundwater,
• Propulsion or Jacking and Lubrication Cans – by adjusting and regulating the atmospheric
Used to exert even jacking force on the MTBM pressures for safe entry to access the cutter face
face for smooth advancement, typically used on for tooling changes

Figure 14. Propulsion or Jacking and Lubrication Cans exert even jacking force Figure 15. A pipe clamp is used when microtunneling within a body of water
for smooth advancement and house lubrication feed valves for the MTBM. to hold the previous pipe segment in place and contend with buoyant forces.

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 ABIS Control Skid

Bentonite Pump

120 VAC Power

MODbus

Automated Injection Automated Injection Automated Injection Automated Injection Automated Injection Automated Injection
Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve
Bentonite Flow Assembly #6 Assembly #5 Assembly #4 Assembly #3 Assembly #2 Assembly #1

Remote Station Remote Station

Control Box #2 Control Box #1
Jacking Shaft

Figure 16: The ABIS system is used to automatically deliver bentonite at specific intervals from a touch screen monitor.

MICROTUNNELING GUIDANCE SYSTEM

Design criteria Installation accuracy is maintained

using active laser guidance systems. Navigation
control is one of the key elements for successful
microtunneling.
The shaft station reference laser is positioned
on line and grade behind the jacking frame and
protected from disturbance. The laser from the
shaft station is projected down the tunnel onto the
MTBM’s target.
The Akkerman standard active guidance system
includes an active target and the MTBM contains
three inclinometers that read and transmit data to
the operator at the control console (see Figure 17). Figure 17. Front MTBM inclinometer; one of three.
Two inclinometers located in the target and the rear
of the MTBM track roll and incline and a third in
the front of the MTBM assesses incline. Sensors in

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 METHOD OF OPERATION - MICROTUNNELING

the target relay this data to the operator’s control

console.
An active laser target is mounted in the back center
of the MTBM (see Figure 18). The pipe laser beam
in the jacking shaft is directed up the tunnel at the
design’s line and grade and projects onto the back
of the MTBM’s active laser target. The laser beam’s
position is calculated and numerically displayed on
the operator’s control console.
The guidance system reports the MTBM’s pitch,
yaw, and X and Y coordinates to the control console
for operator assessment. These coordinates plus Figure 18. The MTBM active target is mounted in the back center of the MTBM.
steering position and inclinometer data inform the
operator of the MTBM’s location at 10-feet ahead
(see Figure 19).
The guidance system software reads the location of
the most intense light. Active laser guidance systems
are subject to tunnel refraction and diffraction which
presents a diminished laser at extended lengths
and cannot be configured for curved alignments
because of interruptions in the line of sight. At
greater distances the laser’s intensity becomes
more dispersed and tunnel temperature variations
can cause laser curvature. Where project conditions
permit, tunnel ventilation can be used to reduce
laser distortion. For these reasons, active laser
navigation systems are recommended for use on
straight microtunnels up to 700-feet.
Figure 19. Active target data numerically displaced on the operator’s control
console screen.

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AZ100 TOTAL GUIDANCE SYSTEM measurement prisms to provide reference points for
guidance system location and azimuth.
Exclusive to Akkerman, the AZ100 Total Guidance
System (TGS) is an azimuth based tunneling After an initial underground survey has been
navigation system with self-leveling station units conducted, reference prisms are installed on the
that is used for extended and curved tunneling, launch shaft wall to determine bearing. Next the
pipe jacking and microtunneling applications. It shaft station and prism are placed on a self-leveling
comprises individual, self leveling, station units tribrach according to the design axis behind the
that maintain a location measurement connection thrust wall (see Figure 20). The first pipe station is
throughout the alignment without continuous added at 300-linear feet (see Figure 21, 22) and
manual surveying. The system interfaces with additional pipe stations are added as required along
the standard Akkerman MTBM target but can be the alignment to maintain a line of sight among
configured with any manufacturer’s target. stations. On average, a 1,000-3,500-linear feet
range of distance can be achieved and is dependent
The most significant point of differentiation between upon prism size, tunnel diameter and atmospherics.
the AZ100 TGS and other tunneling navigation
systems is that an initial survey to ascertain tunnel The AZ100 TGS has proven to be most economical
starting and end points is the only survey that is on straight and curved critical alignments exceeding
required; therefore, downtime is pointedly reduced 700-feet, for any 48-inch ID or larger microtunneling
for uninterrupted mining. project or 72-inch minimum pipe jacking or tunneling
operation. After a contractor’s initial investment, the
The system comprises a jacking shaft station pipe and station units can be modified for a large
and several pipe stations that look to stationary variety of project designs.
Microtunneling Control Container

LAN & Power

Reference Prism Reference Prism

Measurement Prism
TGS--100
Shaft Station Laser Target
Tribrach
Station Network Unit (SNU)

MTBM

Jacking Shaft

Figure 20: The AZ100 TGS shaft station is positioned behind the thrust block in a microtunneling operation.

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 METHOD OF OPERATION - MICROTUNNELING

LAN & Power

Reference Prism Reference Prism

Prism Recognition and Electronic

Distance Measurement

Pipe Station
Measurement Prism
TGS-100
Laser Target
Power & LAN

Self-Leveling Tribrach 300-lf. MTBM

Station Network Unit (SNU)

Jacking Shaft

Figure 21: The AZ100 TGS pipe stations are added throughout the tunnel to maintain a line of sight between all stations.

AZ100 TOTAL GUIDANCE SYSTEM >> STRAIGHT TUNNEL

Measurement
Reference Prism
Prism

Pipe
Station #1
Shaft
Station
Reference
Prism TGS-100
Target
Jacking Shaft
Receiving Shaft

AZ100 TOTAL GUIDANCE SYSTEM >> CURVED TUNNEL

Measurement
Prism
Pipe Pipe
Station #2 Station #1

Reference
Prism

TGS-100
Target

Shaft
Reference Station
Prism
Receiving Shaft
Jacking Shaft

Figure 22: AZ100 TGS station unit set-ups on straight and curved alignments.

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NOTES:

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DRIVEN FOR CUSTOMER SUCCESS
Since 1973, Akkerman has developed,
manufactured and supported quality
pipe jacking and tunneling solutions that
accurately install a variety of underground
infrastructure. We are proud to be the only
North American manufacturer of our range of
equipment and a global competitor.

Symmetry with contractors has been the

backbone of our business and a point of
distinction above our competition. Before
Akkerman the equipment manufacturer there
was D. H. Akkerman Construction Company.
To satisfy their need to accurately install pipe
under crossings, the manufacturing branch of
Akkerman was founded over forty five years
ago.

Our business operates with the highest level

of integrity and Akkerman employees have
a personal investment in our customers’
success. Our highly skilled sales team has
a clear understanding of industry demands.
Our in-house engineering department applies
the most current standards and continually
reviews, reassesses and enhances our
equipment offerings.

We are committed to making every effort to

position our equipment on your next project.
As an added benefit, the purchase of a
complete equipment system includes crew
training and technical support. Akkerman
systems are available for purchase, lease-to-
purchase, or rent from our rental fleet. Select 58256 266th Street Brownsdale, MN 55918 | USA
equipment will be considered for trade-in. Ph.: +1 (800) 533.0386 | akkerman.com
Contact us to pair the best equipment options
with your requirements.
rev. 043019