The Häny HBS Backfill Grouting System is designed for pressure-controlled grouting behind TBM tunneling, allowing for both full annulus and invert segment filling. It features programmable automation for grouting operations, using standard pumps and touch screen controls for real-time monitoring of pressure and quantity. The system is versatile, enabling pre-excavation grouting, maintenance operations, and efficient mixing and injection of materials.

1. 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.

2. The Häny HBS backfill grouting system always uses one
This highly flexible system is based on standard pump
grout pump for each point of injection. It can be adapted
components and various control options to allow different
for either mixing pre-blended dry mortar, or for using
degrees of automation.
ready-mixed mortar.
Touch panel
(TBM Control room)
Main control
Mixer
Agitator
Pumps
P4
P4
P1
P1
P2
Agitator car
P2
P3
P3
Pressure
Transducers
Control functions
Control by pressure
The injection pressure is continuously measured by
accelerator is added to the grout mix, the dosing pumps
means of transducers mounted in or close to the tail
can be switched off earlier to avoid setting of the mortar in
shield injection pipe of the TBM. A PLC with touch screen
the grout lines.
panel monitors and controls the pre-set pressure range
for that specific line. If pressure reaches the pre-set max-
The entire backfill process is controlled from a touch screen
imum the pump automatically stops, to start again auto-
panel, placed either in the main TBM control room or at
matically when pressure hits the lower limit.
the main control cabinet. A window, showing the schematic
of the tail shield allows the TBM or grouting operator to
Once each pump is activated, plc control function is fully
start and stop the grout pumps.
automatic. If the pressure at the injection point fails to
increase to the required pressure within an adjustable
It also shows the pressure at the tail shield grout pipes; the
time limit after start of pumping, an alarm triggers imme-
pressure at the pumps; the pumping rate and total quantity
diate attention by the operator.
pumped by each pump; as well as the accumulated injection
values for all pumps.
Control by quantity
In cases where only the invert is to be grouted, the desired
Quantities are measured by either counting the pump
quantity of grout can be pre-set. Whenever this quantity
strokes or recorded by inductive flow meters and are dis-
is reached, the pump will automatically be stopped. If an
played in a control screen window that also indicates the

3. values for the last 20 shoves and the total quantity of
grout pumped since the start of the project.
Recording of quantity.
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.
Space saving, vertical
arrangement of the pump.
Pump and alarm settings.
Integral system
By complimenting the HBS with a Häny HCM series high-
The main control comprises a plc and all the high voltage
shear mixer, several other operations are possible. Ben-
components necessary for the operation of the grout
tonite, for example, can be mixed in place to clean out the
pumps. For maintenance and cleaning, a switch allows
grout lines for longer periods of downtime. The same equip-
direct control of the pump at the grout station while a
ment can also be used if pre-excavation grouting is required
safety switch prevents unauthorised or accidental opera-
to stabilise bad ground conditions. Cement or ultra fine
tion of the system from a remote control panel.
cement is mixed efficiently in the HCM mixer and injected
by the same pumps normally used for backfilling. Since
Maximum pressure and maximum output of each pump
backfilling and pre-grouting processes are never needed
can be manually pre-set at the pump. Through this func-
or executed at the same time, this dual-purpose applica-
tion, the maximum pressure in the system can be limited
tion is importantly cost efficient, saves considerable space
and the output of the pump can be adapted to the advance
on the TBM back-up gantries, and reduces the inventory of
rate of the TBM. The fine control is affected through the
equipment that needs to be managed and maintained by
pressure- and quantity-dependent plc control.
the tunnelling crews.

4. 1
2
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
4
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
6
5) Grouting with
continuous mixer for
pre-blended dry mortar
Abdalajis High Speed Rail
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.
Häny AG • Buechstrasse 20 • CH-8645 Jona/Switzerland
Tel. +41 44 925 41 11 • Fax +41 44 923 62 45 • info@haeny.com • www.haeny.com
100 48 17–6/2009–e–fdf
Tunnel. Malaga, Spain.