KEY STRATEGIC COMPONENTS FOR TBM’S MANUFACTURERS

Tunnel Boring Machine Erectors

Galbiati Group has recently built two 4.5 ton- segment erectors for TBM (Tunnel Boring Machine), rotating head, for the excavation of the Qingdao 5-6 metro.

The segments erectors are made up of a fixed structure and a moving one, both made of electro-welded structural metalwork and machined on machine tools.

The fixed part consists of two longitudinal beams on which the sliding guides of wear-resistant material are mounted. The moving part consists of the translating/rotating ring and the pick-up system.

The erectors are equipped with a mechanical pick up unit in order to grasp segments. The mechanical pick up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

  • Swinging = ± 5°
  • Pitch = ± 5°
  • Roll = ± 5°

The erectors have also included a coupling plate equipped with bolt benching machine.

Below photos of the erectors completely assembled at Galbiati workshops.

Erectors technical data:

  • Total beams length = 7,000 mm
  • Overall rotation = ± 200°
  • Translation mouvement speed = N/A
  • Rotational speed = max. 2 rpm
  • Maximum load  = 4,500 Kg
  • Weight = ~ 25 ton

Intrados diameter  = 5,400 mm

1. Tunnel Boring Machine Segment Erector

We have recently realized one 4 ton- segment erector for a TBM (Tunnel Boring Machine) designed for an excavation project outside Mae Ngat, Thailandia.

The Tunnel Boring machine, for which the segment erector is intended, shall have a cutterhead of 4.9 m in diameter and will be used to excavate an hydraulic tunnel on site.

The erector comprises a rotating structure controlled by two planetary gears with sprocket drives and a crown wheel. The structure is supported by six rollers and moves on chromium-plated tubular guides.

The erector is equipped with a mechanical pick-up unit in order to grasp segments.(pick-up two pins). The mechanical pick-up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

  • Swinging = 6°
  • Pitch = 6°
  • Roll = 6°

Erector technical data:

  • Longitudinal stroke= 1,800 mm
  • Overall rotation = ± 200°
  • Rotational speed = 2 rpm/minute
  • Maximum load  = 4 ton
  • Weight = 19,000 Kg
  • Intrados diameter  = 4,200 mm

Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-erector/

2. Video: Segment erector for TBM

Galbiati Group has recently designed and built a segment erector for TBM (Tunnel Boring Machine), rotating head with a maximum capacity load of 4 ton, for an excavation project in Mae Ngat, in Thailandia.

Below some videos realized at Galbiati workshops ​​during the final testing of the Tbm segment Erector.

  • Axial stroke of the erector.

Link to Youtube: https://www.youtube.com/watch?v=zKGHL7jKio0

  • Mechanical pick up unit movement.

Link to Youtube: https://www.youtube.com/watch?v=Pb68K-Aungs

  • 90° rotation of segments.

Link to Youtube: https://www.youtube.com/watch?v=uE7L0-OdXGI

  • Tilting of gripper.

Link to Youtube: https://www.youtube.com/watch?v=DE-HPX9E_yY

Link to our website: http://galbiatigroup.it/custom-built-machines/video-erector/

3.Segment Erector for Tunnel Boring Machine

Galbiati Group has recently realized one 3.5 ton- segment erector for a TBM (Tunnel Boring Machine) designed for an excavation project outside Shanxi, China.

The erector comprises a rotating structure controlled by two planetary gears with sprocket drives and a crown wheel. The structure is supported by six rollers and moves on chromium-plated tubular guides.

Below photo of the TBM segment erector set up entirely in the assembly area of Galbiati’s workshop.

The erector is equipped with a mechanical pick-up unit in order to grasp segments. (pick-up two pins).The mechanical pick-up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

  • Swinging = 6°
  • Pitch = 6°
  • Roll = 6°
  • Axial and radial empty stroke of the erector.

Link to Youtube: https://www.youtube.com/watch?v=SH0QxgN67qY

  • Pick up operation and radial and axial translation of the erector.

Link to Youtube: https://www.youtube.com/watch?v=M0b2cIhikfM

Erector technical data:

  • Longitudinal stroke= 1,600 mm
  • Overall rotation = ± 200°
  • Rotational speed = 2 rpm/minute
  • Maximum load  = 3.5 ton
  • Weight = 13,500 Kg
  • Intrados diameter  = 3,400 mm

Link to our website: http://galbiatigroup.it/custom-built-machines/erector-tbm/

4. Cutterhead Supports for tunnel boring machine (TBM)

We have recently developed two Cutterhead Supports for the cutter head of a TBM designed for an excavation project in Albania.

Below are a few photos of the TBM control units set up entirely in the assembly area of Galbiati’s factory

Some technical data of the Cutterhead supports: a bearing support 4.2 metres wide with a roller bearing 3.2 metres in diameter, 10 planetary gears with a transmitted power of 210 kW each, and a lubrication system. Gross weight: 60 tons.


Handling of the Cutterhead supports at Galbiati’s factory and the subsequent packaging and transport of these were particularly complex due to the size and weight of the supports.

The Tunnel Boring machine in question, for which the control units were intended, will have a cutter head for drilling a tunnel on site for the promising “Devoll Hydropower Project” in Albania. The project will involve use of the water resources of the River Devoll which is about 70 km long and situated south-east of the capital of Tehran, and the construction of a water supply network at Moglicë and Banjia, comprising a hydraulic tunnel in the rock about 6.7 km long. The project is expected to be completed by 2018 and will produce about 729 GWh of electricity a year, providing Albania with a 20% annual increase in electrical energy.

Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-control-units/

5. Tunnel Boring Machine Erectors

Galbiati has recently developed two 7.5 ton- segment erectors for two hard rock double shield TBMs (Tunnel Boring Machines) designed for an excavation project outside Pfunds, Austria.

The segments erectors are made up of a fixed structure and a moving one, both made of electro-welded structural metalwork and machined on machine tools

The fixed part consists of two longitudinal beams on which the sliding guides of wear-resistant material are mounted. The mobile part, instead, comprises a fixed ring and a rotating one controlled by two planetary drives with sprockets coupled with the fifth wheel coupling with internal teeth. The segments that make up the ring are 6: the “invert” segment, or base segment, that weighs 7.5 tons, and five segments (four shoulder segments and a key segment) each weighing 6 tons.

The erectors are equipped with a mechanical pick-up unit in order to grasp segments. The mechanical pick-up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

  • Swinging = 5°
  • Pitch = 5°
  • Roll = 5°

A prob-drill is also provided with the erectors for carrying out additional drilling operations.

Below photos of the erectors completely assembled at Galbiati workshops.

Erectors technical data:

  • Total beams length = 7,000 mm
  • Overall rotation = 220° on both sides
  • Rotational speed = 2 rpm/minute
  • Maximum load  = 7,500 Kg
  • Weight = 32,000 Kg
  • Intrados diameter  = 6,300 mm

The Tunnel Boring machines in question, for which the segments erectors were intended, will have a cutter head 6.5 metres wide and will be used to drill a hydraulic tunnel for the promising hydroelectric project “Gemeinschaftskraftwerk Inn”. The project will involve the construction of a water supply network in Tyrol, comprising a hydraulic tunnel about 22.6 km long that will be drilled using two hard rock double shield TBMs. The network will take 4 years to complete (2014-2018) and the hydraulic tunnel will produce about 400 GWh of electricity a year from renewable sources, providing energy for more than a hundred thousand homes.

Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-segments-erectors/

7. Cutterhead Supports for tunnel boring head (TBM)

Galbiati recently designed control units (Cutterhead Supports) for the rotating head of an EPB (Earth Pressure Balance) tunnel boring machine for an excavation project in Mexico City, Mexico.

Below are a few photos showing the TBM cutterhead supports made entirely in the assembly area of Galbiati’s factory.

A few technical details of the control units: cutterhead support measuring 4.5 m in diameter with roller bearing measuring 4 m in diameter, 11 planetary gear units with two-speed gearbox – transmitted power of 330KW each, lubrication system. Overall weight 130 tons.

Link to our website: http://galbiatigroup.it/custom-built-machines/cutterhead-support/

8. Cutterhead Supports for tunnel boring head – TBM

The control units (Cutterhead Supports) designed for an excavation project in Mexico at Galbiati’s factory proved to be a challenge to handle, pack and transport due to the sheer size and weight of the support.

The EPB (Earth Pressure Balance) for which the control units were designed will have a boring head measuring 8.7 metres in diameter and will be used on site to excavate a tunnel for sewerage.

The EPB (Earth Pressure Balance) TBM will be assembled at the site early to mid 2015 and the machine shall be fully operational on site before the summer.

Below are a few photos of the TBM cutterhead supports handled and packed in the assembly area of Galbiati’s factory.

Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-main-bearings-2/

9. Tunnel Boring Machine Erectors

Galbiati Group has recently built four 4.5 ton- segment erectors for TBM (Tunnel Boring Machine), rotating head, for the excavation of the Qingdao metro.

The segments erectors, built by Galbiati, are identical for both weight and size. They are made up of a fixed structure and a moving one, both made of electro-welded structural metalwork and machined on machine tools.

The fixed part consists of two longitudinal beams on which the sliding guides of wear-resistant material are mounted. The moving part consists of the translating/rotating ring and the pick-up system.

The erectors are equipped with a mechanical pick up unit in order to grasp segments. The mechanical pick up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

  • Swinging = ± 5°
  • Pitch = ± 5°
  • Roll = ± 5°

Below photos of the erectors completely assembled at Galbiati workshops.

The erectors have also included a coupling plate equipped with bolt benching machine.

Erectors technical data:

  • Total beams length = 7,000 mm
  • Overall rotation = ± 200°
  • Translation movement speed = N/A
  • Rotational speed = max. 2 rpm
  • Maximum load  = 4,500 Kg
  • Weight = ~ 25 ton
  • Intrados diameter  = 5,400 mm

Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-erectors/

10. Video: Segment erector for TBM

Galbiati Group has recently designed and built a segment erector for TBM (Tunnel Boring Machine), rotating head with a maximum capacity load of 4.5 ton, for an excavation project in San José de Minas in Ecuador.

Below some videos realized at Galbiati workshops ​​during the final testing of the Tbm segment Erector.

Axial and radial empty stroke of the erector.

Link to Youtube: https://www.youtube.com/embed/Apxa9-yD_DU

Pick up operation.

Link to Youtube: https://www.youtube.com/embed/SoW100G9Drk

Pick up operation and radial and axial translation of the erector.

Link to Youtube: www.youtube.com/embed/L8TczVRHAVs

Link to our website: http://galbiatigroup.it/custom-built-machines/video-tbm-segment-erector/

11. Cutterhead supports for tunnels boring machinery head (TBM)

Galbiati Group builds TBM components for the most important tunnel boring world leaders such as planetary gearboxes, bearing supports (Cutterhead supports), erectors.

Galbiati has recently developed Cutterhead Supports for tunnel TBM rotary boring heads, built for an excavation project in Australia, Queensland.

Here is some technical data for the bearing supports: Cutterhead supports for 5.8 m diameters, with d roller bearings 5,3 mt, 16 planetary gearboxes –Transmitted power of 550 KW each, a lubrication system. Total weight 160 tons.

The movement of the Cutterhead Supports inside the Galbiati workshop and the subsequent packaging and transportation has been particularly complex given the size and weight of the support.

The TBM (Dual Mode EPBM),  in question, which the  bearing supports  were intended for, shall have an overall diameter of 8 meters, and will perform the digging of the two tunnels providing access to a coal mine.  The particular inclination of the tunnel and the massive presence of methane gas will be the two main difficulties encountered during the excavation of the mine.

The work site assembly of the TBM is scheduled for July 1, 2013 and the machine will be fully operational on site between October-November 2013.

Here are some photos of the Cutterhead Supports fully implemented at the mounting area of the Galbiati workshops.

Link to our website: http://galbiatigroup.it/custom-built-machines/cutterhead-supports/

12. Testing at the Aprilia plant: Segment erector for TBM

Galbiati Group has set up a group of four segment erectors for each TBM for the Copenhagen Metro excavation project

It was inaugurated in the Aprilia production factory on May 10 2013, the second TBM EPB, (better known as the tunnel boring machine and hence acronym TBM), built by the SELI SpA company, specializing in the excavation of underground tunnels and in the design and implementation of TBM excavation equipment.

The “TBM EPB”, capable of drilling a tunnel with a diameter of 5.78 meters, is an extraordinary giant machine and is the second of a group of four excavation boring machines (this is the technical name), which should be able to create 2 tunnels for a total of 32 km of underground excavations for the fully automated metro line in Copenhagen, which, passes through the city centre providing 17 stations, this will all come into operation by 2018.

It was for this criticality in terms of excavation that SELI was chosen as the contractor of the whole construction project of the four “TBM EPB” for the Copenhagen Metro. The TBM EPB (Earth Pressure Balance) machine, built by Seli in collaboration with Kawasaki, can in fact excavate the ground up to thirty meters deep, providing much greater stability, using the excavated material and maintaining the pressure at the front.

At the testing of the second TBM EPB on May 10, 2013 at the Aprilia plant, Galbiati Group was also invited, the Italian group recognized internationally for the quality of its manufacturing and mechanical engineering, specializing in particular in the design and construction of machinery and equipment with high technological content.

Galbiati Group was in fact commissioned by Seli, the Roman Contact for the design and implementation of a group of 4 segment positioning erectors, one for each TBM EPB rotating head.

The erector constructed from Galbiati for the second TBM EPB has a diameter of 4,100mm, a maximum capacity of about 4,000 Kg, a total weight of approximately 25,000 Kg and a maximum rotation of  2 rpm.

Afterwards, the video of the testing phase of the segment erector:

Link to Youtube: http://www.youtube.com/embed/gtUi-nSyRaI

Projects like the one just described have enabled the Galbiati Group to be a market leader in Europe and abroad in the design and construction of manufactured systems at the limit of the current field of metallurgical technology and mechanical engineering. After a sudden slowdown in investments in the industrial sector and a slow recovery as the one we are going through, attention to innovation and high-tech production is in fact the only solution to compete globally.

Link to our website: http://galbiatigroup.it/custom-built-machines/segment-erector/

13. Segment erector for TBM

Manufacture of a segment erector for a TBM (Tunnel Boring Machine) rotating head for tunnel excavation.

The segment erector built by Galbiati is equipped with a mechanical arm with suction cup, so-called vacuum pick up system, positioned in the rear are of the mantle (tail) with the function of moving and put in place the definitive coating segments of the tunnel.

The erector picks up the piece form the sled with a vacuum pick up system with three suction cups (one suction cup is sufficient to support the weight of a segment, to avoid the loss of the load in case of average) and places it in its seat. On proceeds in succession until the last segment (the key segment), which puts in compression the ring. The segments of a ring are bolted together in a radial direction and are connected to the previous ring by means of connectors.

Below the link during the segment erector testing phase at Galbiati Group workshop.

Link to Youtube: http://www.youtube.com/embed/gtUi-nSyRaI

Link to our website: http://galbiatigroup.it/custom-built-machines/erector-for-tbm/

14. Tunnel Boring Machine Erector

Galbiati Group has recently built a 4.5 ton- segment erector for TBM (Tunnel Boring Machine), rotating head, for the excavation of the Bangalore metro.

The segment erector, built by Galbiati, is made up of a fixed structure and a moving one, both made of electro-welded structural metalwork and machined on machine tools.

The fixed part consists of two longitudinal beams on which the sliding guides of wear-resistant material are mounted. The moving part consists of the translating/rotating ring and the pick up system.

Usually positioned behind the cutterhead, the erector is equipped with a mechanical pick up unit in order to grasp segments. The mechanical pick up unit grasps and retains segments for the entire duration of the positioning operations with three independent movements:

  • Swinging = ± 5°
  • Pitch = ± 5°
  • Roll = ± 5°

Below there is a photo of the erector being assembled.

Erector technical data:

  • Total beams length: 7,000 mm
  • Overall rotation = ± 200°
  • Translation movement speed = 2.800*45 mm/s
  • Rotational speed = 2 revolutions per minute
  • Maximum load  = 4,500 Kg
  • Weight = 27,000 Kg
  • Intrados diameter  = 5,600 mm

Link to our website: http://galbiatigroup.it/custom-built-machines/tunnel-boring-machine-erector/

15. Cutterhead supports for TBM (tunnel boring machines)

Cutterhead supports of the TBM (Tunnel Boring Machine) rotating head, excavation diameter from 4 m to more than 12 m. Cutterhead support diameter 5400 mm, with 4000 mm diameter roller bearing and ring gear module 22, nine helical gears with module 22 nine planetary gears with module 22 mm output pinion and lubricating system. Overall weight of cutterhead supports: 100 ton.

Cutteread supports used on TBM machine for excavating water conduits in Ethiopia and China.

Link to our website: http://galbiatigroup.it/custom-built-machines/tbm-cutterhead-supports/

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