SAFE WORKING IN
TUNNELING
For tunnel workers and first line supervision
SAFE WORKING IN
TUNNELING
This document is written
for tunnel workers
and first line supervision
Prepared by the ITA Working Group
‘Health and Safety’
and financed by BG BAU and ITA
1 The Tunneller’s Equipment 4
1.1 .........Personal Safety Outfit ............................................................................. 6
1.2.........Personal Safety Outfit ............................................................................. 8
1.3.........Personal Safety Outfit ...........................................................................10
2 Tunnel Installations 12
2.1 .........Ventilation .................................................................................................14
2.2 ........Lighting ......................................................................................................16
2.3 ........Electrical Installations and Supply Lines ........................................18
2.4 ........Emergency Equipment .........................................................................20
3 Walkways to Working Places 22
3.1 .........Walkways with Rubber-Tyred Vehicles ...........................................24
3.2 ........Walkways with Track Operation ........................................................26
3.3 ........Passenger Transport ..............................................................................28
3.4.........Transport in Shafts .................................................................................30
3.5 ........Access and Work Places on Ladders ................................................32
4 Excavation 34
4.1 .........Manual Drilling ........................................................................................36
4.2 ........Jumbos .......................................................................................................38
4.3 ........Charging the Blast Holes......................................................................40
4.4.........Blasting .......................................................................................................42
4.5 ........Excavation with Excavator.................................................................. 44
4.6 ........Excavation with Roadheader..............................................................46
5 Primary Support 48
5.1 .........Scaling.........................................................................................................50
5.2 ........Manual Scaling.........................................................................................52
5.3 ........Installing Wire Mesh ..............................................................................54
5.4.........Installing Ribs and Girders ...................................................................56
5.5 ........Setting Rock Bolts...................................................................................58
5.6.........Shotcrete Application ...........................................................................60
5.7.........Shotcrete Manipulator ..........................................................................62
5.8 ........Shotcrete Machinery .............................................................................64
5.9.........Maintenance of Shotcrete Plant / Equipment ..............................66
5.10.......Removing Obstructions .......................................................................68
6 Transport 70
6.1 .........Mucking Out .............................................................................................72
6.2 ........Travelling Past Working Areas ............................................................74
6.3 ........Driving Past the Edge of an Excavation..........................................76
6.4 ........Turning in Tunnels ..................................................................................78
6.5 ........Reversing in Tunnels ..............................................................................80
6.6 ........Narrow Areas where Rail Vehicles are used ..................................82
6.7.........Belt Transport ...........................................................................................84
6.8 ........Belt Transport (belt transfer points).................................................86
6.9.........Shaft Transport (removal of excavated material)........................88
6.10.......Shaft Transport (bulk loads) ................................................................90
7 Final Lining 92
7.1 .........Installing Steel Reinforcement...........................................................94
7.2 .........Tunnel Formwork Access .....................................................................96
7.3 .........Working in the Tunnel Formwork .....................................................98
8 TBM-Work 100
8.1 .........Maintenance Work in Cutterhead Area ....................................... 102
8.2 ........Installing Rockbolts in TBM Tunnels ............................................. 104
8.3 ........Track Laying in TBM Tunnels............................................................ 106
8.4 ........Installing Segments (big tunnel).................................................... 108
8.5 ........Installing Segments (small tunnel).................................................110
9 Toxic Substances in the Breathing Air 112
9.1 .........Diesel Vehicle Emissions.....................................................................114
9.2.........Dust Emission .........................................................................................116
10 First Aid 118
10.1.......Rescue Chain ..........................................................................................120
10.2 ......Rescue Chain ......................................................................................... 122
Picture Proof / Acknowledgements...............................................124
1
4
The Tunneller’s Equipment
5
1.1
6
Personal Safety Outfit
7
• hard hat
• safety shoes (boots)
• gloves
• protective clothing
• self rescuer
• other personnel protective equipment
(depending on working process)
1.2
8
Personal Safety Outfit
9
1• eye protection
2• hard hat
3• respiratory protection
4• gloves
5• ear muffs
6• ear plugs
7• safety boots
1.3
5
1
10
Personal Safety Outfit
11
1• high visibility protective clothing
2• self rescuer
3• reflecting warning vest
4• hard hat for shotcreting
5• hand lamp
6• cap lamp
2
12
Tunnel Installations
www.tunnel-baumleite.de
13
2.1
14 Ventilation
Gefahr
• sufficient ventilation
• test and measure at regular intervals
• avoid re-circulation from the portal
Ventilation
Schutz
Fresh air ducts 15
• extend close to the working face
• avoid kinks
• repair any damage immediately
2.2
16 Gefahr
• light all work places and access ways
• install special lighting at dangerous places
• use flashing warning lights adjacent to dangerous locations
Lighting
Schutz 17
• all light fittings should be protected against ingress of water
• check, maintain and clean lighting installations regularly
• safety lighting system (emergency lighting)
2.3
18 Gefahr
• all electrical installations to be set, modified and repaired
by qualified electricians;
(work on high voltage network [transmission or power lines]
only permitted with a special authorisation)
• adhere to national requirements
• use earth fault circuit breaker ≤ 30 mA
Electrical Installations
and Supply Lines
Schutz 19
• support cables and pipelines securely on brackets
against risks of impact, bending, abrasion, tension
• use appropriate fittings and coupling system
2.4
20 Gefahr
• give regular instructions on emergency drills
and rescue procedures
• carry out emergency drills with the participation
of the fire-brigade
• provide effective emergency communications
(check regularly)
Emergency Equipment
Schutz 21
• set up first aid and rescue installations
• set up appropriate fire extinguishers
(observe fire classification)
• provide self-rescuers of sufficient number and size
3
22
Walkways to Working Places
23
3.1
24 Gefahr
Danger
• being struck / run over
Walkways with
Rubber-Tyred Vehicles
Schutz
Protection 25
• separate paths for vehicles and pedestrians
• install guard rails alongside the pedestrian path
• maintain roadway surface and wet it to reduce dust
• omit obstacles in vehicle path
3.2
26 Danger
• being struck / run over
• slipping and tripping hazards
Walkways with Track Operation
Protection 27
• separate path for vehicles and pedestrians
• put locos at the ends
• provide a video monitoring system to observe
ahead of train when pushing
• use rail personnel carriers
3.3
28 Danger
• falling
• being struck / run over
Passenger Transport
Protection 29
• do not ride on equipment
• provide and use suitable vehicles for passenger transport
3.4
30 Danger
• falling from the ladder
• being crushed by the skip
• fall of excavated material
Transport in Shafts
Protection 31
• install safety hoops and intermediate landings
• do not overload skip
• use either diagonal ladderways, stair tower or personnel lift
• do not carry heavy items
3.5
32 Danger
• falling
Access and Work Places on Ladders
Protection 33
• remove damaged ladders from site
• put both feet on the rung and do not
reach over too far while working
• do only simple and close work on ladders
4
34
Excavation
35
4.1
36 Danger
• slipping and falling
• dust, noise
Manual Drilling
Protection 37
• adopt safe working position – worker as well as drilling tool
• wet drilling
• wear hearing and eye protection
4.2
38 Danger
• being knocked over, being crushed, being struck
• rock fall
• dust, noise
Jumbos
Protection 39
• keep away from danger zone
• wet drilling
• wear hearing protection
4.3
40 Danger
• accidental detonation by drilling into explosives
• being knocked over or crushed by drilling boom
• falling
Charging the Blast Holes
Protection 41
• only charge after the whole face has been completely drilled
• work can only be carried out under the supervision
of an authorized and qualified blasting specialist
• use working platforms
4.4
42 Danger
• fly rock
• toxic fumes resulting from blasting
Blasting
Protection 43
• keep away from the blasting zone
• switch off the ventilation before blasting
• switch on the ventilation at full capacity after blasting
• the team shall stay in a protective shelter
(safety container or blasting shelter) after blasting
• in small tunnels the protective shelter can be installed
in a niche
4.5
44 Danger
• being crushed
• being run over
Excavation with Excavator
Protection 45
• do not enter danger zone
• light the working area adequately
• use acoustic signal when driving backwards
• visual monitoring of the rear zone of vehicle
4.6
46 Danger
• dust containing quartz (silicosis)
• being crushed
• being run over
• flying debris
Excavation with Roadheader
Protection 47
• install effective dust control system
• use pilot tunnel for dust extraction
• install waterspray system at cutting head
• do not enter danger zone of machine
• light the working area adequately
5
48
Primary Support
www.tunnel-baumleite.de
49
5.1
50 Danger
• rock fall
• instability / collapse of working face
Scaling
Protection 51
• use excavator for rock scaling
• do not enter the danger zone before scaling completed
• light the working area adequately
5.2
52 Danger
• rock fall
• falling from heights
• being crushed
Manual Scaling
Protection 53
• only work from a safe area
• use working platforms
• light the area adequately
5.3
54 Danger
• falling
• being crushed
Installing Wire Mesh
Protection 55
• use working baskets
• do not enter the danger zone
• light the area adequately
5.4
56 Danger
• falling from heights
• being crushed
• lack of adequate lighting
Installing Ribs and Girders
Protection 57
• use safe equipment
• use machinery according to its intended use
• do not enter the danger zone
5.5
58 Danger
• falling from heights
• noise
Setting Rock Bolts
Protection 59
• use working baskets of jumbo
• wear eye and hearing protection
5.6
60 Danger
• falling from heights
• rebound
• dust
• chemical additives
Shotcrete Application
Protection 61
• use shotcrete manipulator
• use protective clothing
• wear eye protection
• wear respiratory protection
5.7
62 Danger
• being crushed
• shotcrete detachment
• rebound
• dust
• burst of shotcrete hose
Shotcrete Manipulator
Protection 63
• do not enter the danger zone
• distance between nozzle and wall ≤1,5 m
• wear shotcrete protective helmet
• wear respiratory protection
• wet mix concrete with non toxic additive
to reduce dust and atmospheric pollution
5.8
64 Danger
• dust containing quartz (silicosis)
• skin and eye irritation resulting from toxic accelerator
Shotcrete Machinery
Protection 65
• use wet shotcrete machinery
• use dry mix sprayed concrete with shotcrete cement
(without accelerator
• alternative: use moist aggregates (with non toxic accelerator)
• use a nozzle with pre-dampening system
5.9
66 Danger
• crushed limbs as a result of the machine being
unintentionally switched on
• skin and eye irritation resulting from the spillage of
toxic accelerator
Maintenance of
Shotcrete Plant / Equipment
Protection 67
• clean the equipment with high pressure water jet
• machine must be switched off when cleaning inside it
• use non-toxic accelerator
• wear eye protection
5.10
68 Danger
• injury resulting from the hose whipping about
• danger when opening the clogged up shotcrete hose
Removing Obstructions
Protection 69
• take hold of the end of the hose
• do not enter the danger zone where shotcrete is being ejected
• the operator shall monitor the danger zone
• wear eye protection
6
70
Transport
www.tunnel-baumleite.de
71
6.1
72 Danger
• being struck
• being crushed
• falling material
• dust, noise
• tripping, falling
Mucking Out
Protection 73
• do not enter the loading area (danger zone)
• keep the running surface in good condition
• do not overload dumper
• light the loading zone adequately
6.2
74 Danger
• being run over
• falling material
Travelling Past Working Areas
Protection 75
• use flashing warning lights at working areas
• keep a safe distance, drive slowly
• do not overload dumper
• light all working places adequately
6.3
76 Danger
• the vehicle could tip over
• falling material
Driving Past the Edge of
an Excavation
Protection 77
• maintain a safety distance from edge
• place guard barriers at the edge of ramp incline
• drive slowly on ramp incline
• do not overload dumper
6.4
78 Danger
• being run over
• being crushed
Turning in Tunnels
DANGER!
VEHICLE TURNING AREA
Protection 79
• do not enter the danger zone
• visual monitoring of the rear zone of vehicle
• mark turning area, provide adequate surface
and light it adequately
6.5
80 Danger
• being struck or run over
Reversing in Tunnels
Protection 81
• separate paths for vehicles and pedestrians
• visual monitoring of the rear zone of vehicle
• regularly clean vehicle mirrors and lights and replace
defective ones
• light the area adequately
• wear reflective clothing
6.6
82 Danger
• being crushed
• being struck / run over
• tripping up
Narrow Areas
where Rail Vehicles are used
Protection 83
• keep clear of track and rail vehicles when under operation
• separate railway area and pedestrian path
• keep pedestrian path clear of material and obstructions
6.7
84 Danger
• being trapped or drawn in by running conveyor
Belt Transport
Protection 85
• protection against drawing in
• conveyor belt and walkways should be delimited / separated
• place safety switches at regular space interval
6.8
86 Danger
• harmful dust
Belt Transport
(belt transfer points)
Protection 87
• transfer points should be equipped with a waterspray system
• alternative: housing in with dust extraction system
6.9
88 Danger
• being crushed
• falling material
Shaft Transport
(removal of excavated material)
Protection 89
• do not enter the danger zone under skip
• supervise movements of skip
• instruct hoisting equipment operator by signals,
radio or telephone
6.10
90 Danger
• being injured by falling or swinging load
Shaft Transport (bulk loads)
Protection 91
• do not stand under load
• sling loads properly
• instruct hosting equipment operator by radio or telephone
7
92
Final Lining
93
7.1
94 Danger
• falling
Installing Steel Reinforcement
Protection 95
• install side-guards
• use a telescopic working platform
• make sure that planking has correctly been put in place
7.2
96 Danger
• falling
Tunnel Formwork Access
Protection 97
• access ways should be properly constructed and guarded
7.3
98 Danger
• tripping and falling
• noise resulting from the external vibrator
• unsafe access and working places
Working in the Tunnel Formwork
Protection 99
• keep the access ways clear of all loose material
• maintain working place in good order
• use self compacting concrete if possible
• wear hearing protection when pouring concrete
8
100
TBM-Work
101
8.1
102 Danger
• falling
• drowning in bentonite
• collapse of excavated faces
Maintenance Work in
Cutterhead Area
Protection 103
• use the platform provided by manufacturer
• ensure face stability
• sheeting plates at workface should be driven up hydraulically
where required
8.2
104 Danger
• rock fall and cave-in
• falling
Installing Rockbolts in TBM Tunnels
Protection 105
• provide safe, defined working place
• keep out of danger zone
8.3
106 Danger
• being crushed
• being struck / run over
Track Laying in TBM Tunnels
Protection 107
• track laying operation shall be stopped
during transport works
• use gates or signalling system (stoplights)
• driving cabs at both ends of train
• driving cab at one end, visual monitoring
at the other end of train
8.4
108 Danger
• falling
• being crushed
Installing Segments (big tunnel)
Protection 109
• provide safe, defined working place, use platform
• do not enter danger zone when segments are being
put in place
• maintain eye / visual contact with segment erector operator
8.5
110 Danger
• being crushed
• being knocked down
Installing Segments (small tunnel)
Protection 111
• do not enter danger zone when segments
are being put in place
• maintain eye / visual contact with segment erector operator
9
112
Toxic Substances
in the Breathing Air
113
9.1
114 Danger
• diesel engine exhaust gas
Diesel Vehicle Emissions
Protection 115
• equip machinery with particle filters
• use low emission diesel engine
• stop engines when idling
• provide sufficient ventilation
9.2
116 Danger
• dust containing quartz (silicosis)
• being crushed
• being run over
• flying debris
Dust Emission
Danger/Protection 117
• provide sufficient ventilation
• extract dust
• wet spray dusty areas
• use appropriate respiratory protection
10
118
First Aid
119
10.1
120 Provide first aid and rescue equipment
• do not move injured person
unless in further danger
Rescue Chain
Emergency call 121
10.2
122 First Aid
• if casualty unconscious turn head to side
to prevent suffocation
Rescue Chain
Transport to medical centre 123
Picture Proof
Front page
Tunnel Jagdberg, Photo: BUNG Ingenieure AG, Knut Johnsen
Last page
Kopswerk II Kavernenkrafthaus, Photo: Jäger Bau GmbH
Page 4: Geodata
Page 12: Tunnel Baumleite, Photo: Wolfgang Sitter
Page 22: Philipp Holzmann AG
Page 34: Tunnel Jagdberg, Photo: BUNG Ingenieure AG, Knut Johnsen
Page 48: Tunnel Baumleite, Photo: Wolfgang Sitter
Page 70: Tunnel Baumleite, Photo: Wolfgang Sitter
Page 92: Tunnel Jagdberg, Photo: BUNG Ingenieure AG, Knut Johnsen
Page 100: Katzenbergtunnel, Photo: Wayss & Freytag Ingenieurbau AG
Page 112: BG BAU Prävention
Page 118: Fluchtstollen Saukopftunnel, Photo: Dr. Uwe Klein
Acknowledgement
ITA would like to thank the German BG BAU
and all the members of working group n°5
for their tremendous work,
Dr. Martin Herrenknecht
of Herrenknecht AG,
Mr. Klaus Langendorf
of Liebherr Hydraulikbagger GmbH,
Mr. Karl-Heinz Wennmohs
of Atlas Copco MCT GmbH
for their support in the graphical design
of this booklet.
