in
York, England, showing the circular cross section of the tunnel with the
overhead line powering a
Eurostar train. Also visible is the segmented tunnel lining. Site investigation undertaken in the 20 years before construction confirmed earlier speculations that a tunnel could be bored through a chalk
marl stratum. The chalk marl is conducive to tunnelling, with impermeability, ease of excavation and strength. The chalk marl runs along the entire length of the English side of the tunnel, but on the French side a length of has variable and difficult geology. The tunnel consists of three bores: two diameter rail tunnels, apart, in length with a diameter service tunnel in between. The three bores are connected by 270 cross-passages and 194 piston relief ducts. It is the third-longest rail tunnel in the world, behind the
Gotthard Base Tunnel in Switzerland and the
Seikan Tunnel in Japan, but has the longest undersea section. The average depth is below the seabed. On the UK side, of the expected of spoil, approximately was used as fill at the terminal site. The remainder was deposited at Lower Shakespeare Cliff behind a seawall,
reclaiming of land. This reclaimed land was later developed into
Samphire Hoe, a
country park. An environmental assessment did not identify any major risks associated with the project, and additional studies on safety, noise, and air pollution were generally positive. However, environmental objections were raised regarding the proposed high-speed rail link to London.
Geology stratum (layer). Successful tunnelling required a sound understanding of topography and geology and the selection of the best rock strata through which to dig. The geology of this site generally consists of north-easterly dipping
Cretaceous strata, part of the northern limb of the Wealden-Boulonnais dome. It has: • Continuous chalk in the cliffs on either side of the Channel, with no major faulting, as observed by
Verstegan in 1605. • Four geological
strata, marine sediments laid down 90–100million years ago;
pervious Upper and Middle Chalk above slightly pervious Lower Chalk and finally impermeable
Gault Clay. There is a sandy stratum of Glauconitic marl (tortia), between the chalk marl and the gault clay. • A layer of chalk marl (French:
craie bleue) in the lower third of the lower chalk appeared to present the best tunnelling medium. The chalk has a clay content of 30–40% making it impermeable to groundwater, yet relatively easy excavation with strength allowing minimal support. Ideally, the tunnel would be bored in the bottom of the chalk marl, allowing water inflow from fractures and joints to be minimised, but above the gault clay that would increase stress on the tunnel lining and swell and soften when wet. On the English side, the stratum
dip is less than 5°; on the French side, this increases to 20°. Jointing and faulting are present on both sides. On the English side, only minor faults of displacement less than exist; on the French side, displacements of up to are present owing to the Quenocs
anticlinal fold. The faults are of limited width, filled with calcite, pyrite and remolded clay. The increased dip and faulting restricted the selection of routes on the French side. To avoid confusion, microfossil assemblages were used to classify the chalk marl. On the French side, particularly near the coast, the chalk was harder, more brittle and more fractured than on the English side. This led to the adoption of different tunnelling techniques on the two sides.
Site investigation Marine soundings and samplings were made by Thomé de Gamond in 1833–67, establishing the seabed depth at a maximum of and the continuity of geological strata (layers). Surveying continued for many years, with 166marine and 70land-deep boreholes being drilled and more than 4,000linekilometres of the marine geophysical survey completed.
Tunnelling Tunnelling was a major engineering challenge; the only precedent was the undersea
Seikan Tunnel in
Japan, which opened in 1988. A serious health and safety risk with building tunnels under water is major water inflow due to the high
hydrostatic pressure from the sea above, under weak ground conditions. The tunnel also had the challenge of timescale: being privately funded, an early financial return was paramount. The objective was to construct two rail tunnels, apart, in length; a service tunnel between the two main ones; pairs of -diameter cross-passages linking the rail tunnels to the service tunnel at spacing; piston relief ducts in diameter connecting the rail tunnels apart; two undersea crossover caverns to connect the rail tunnels, with the service tunnel always preceding the main ones by at least to ascertain the ground conditions. There was plenty of experience with excavating through chalk in the mining industry, while the undersea crossover caverns were a complex engineering problem. The French one was based on the
Mount Baker Ridge freeway tunnel in
Seattle; the UK cavern was dug from the service tunnel ahead of the main ones, to avoid delay. Precast segmental linings in the main
tunnel boring machine (TBM) drives were used, but two different solutions were used. On the French side, neoprene and grout sealed bolted linings made of cast iron or high-strength reinforced concrete were used; on the English side, the main requirement was for speed, so bolting of cast-iron lining segments was only done in areas of poor geology. In the UK rail tunnels, eight lining segments plus a key segment were used; in the French side, five segments plus a key. On the French side, a diameter deep grout-curtained shaft at Sangatte was used for access. On the English side, a marshalling area was below the top of Shakespeare Cliff, the
New Austrian Tunnelling method (NATM) was first applied in the chalk marl here. On the English side, the land tunnels were driven from Shakespeare Cliff—the same place as the marine tunnels—not from Folkestone. The platform at the base of the cliff was not large enough for all of the drives and, despite environmental objections, tunnel spoil was placed behind a reinforced concrete seawall, on condition of placing the chalk in an enclosed lagoon, to avoid wide dispersal of chalk fines. Owing to limited space, the precast lining factory was on the
Isle of Grain in the Thames estuary, Six machines were used; all commenced digging from Shakespeare Cliff, three marine-bound and three for the land tunnels. A gauge railway was used on the English side during construction. In contrast to the English machines, which were given technical names, the French tunnelling machines were all named after women: T1 "Brigitte", T2 "Europa", T3 "Catherine", T4 "Virginie" and T5 "Pascaline", the latter being renamed T6 "Séverine" for the final tunnel bore. After the tunnelling, one machine was on display at the side of the M20 motorway in
Folkestone until
Eurotunnel sold it on eBay for £39,999 to a scrap metal merchant. Another machine (T4 "Virginie") still survives on the French side, adjacent to Junction 41 on the
A16, in the middle of the D243E3/D243E4 roundabout. On it are the words "hommage aux bâtisseurs du tunnel", meaning "tribute to the builders of the tunnel".
Tunnel boring machines The eleven tunnel boring machines were designed and manufactured through a joint venture between the Robbins Company of
Kent, Washington, United States;
Markham & Co. of
Chesterfield, England; and
Kawasaki Heavy Industries of Japan. The TBMs for the service tunnels and main tunnels on the UK side were designed and manufactured by
James Howden & Company Ltd, Scotland.
Railway design , used to carry motor vehicles through the Channel Tunnel. These are the largest railway wagons in the world.
Communications There are three communication systems: • Concession radio – for the tunnel operator's personnel and vehicles within the concession area (terminals, tunnels, coastal shafts) • Track-to-train radio – secure speech and data between trains and the railway control centre • Shuttle internal radio – communication among shuttle crew, and to passengers over car radios
Power supply Power is delivered to the locomotives via an
overhead line at 25 kV AC railway electrification| with a normal overhead clearance of . All tunnel services run on electricity, shared equally from English and French sources. There are two substations fed at 400 kV at each terminal, but in an emergency, the tunnel's lighting (about 20,000 light fittings) and the plant can be powered solely from either England or France. The traditional railway south of London uses a 750VDC
third rail to deliver electricity, but since the opening of
High Speed 1 there is no longer any need for tunnel trains to use it. High Speed 1, the tunnel and the
LGV Nord all have power provided via overhead catenary at 25kV50Hz AC. The railways on "classic" lines in Belgium are also electrified by overhead wires, but at 3,000VDC. The TVM signalling is interconnected with the signalling on the high-speed lines on either side, allowing trains to enter and exit the tunnel system without stopping. The maximum speed is . Signalling in the tunnel is coordinated from a control centre at the Folkestone terminal. A backup facility at the Calais terminal is staffed at all times and can take over all operations in the event of a breakdown or emergency.
Track system Conventional ballasted tunnel track was ruled out owing to the difficulty of maintenance and lack of stability and precision. The Sonneville International Corporation's track system was chosen because it was reliable and also cost-effective. The type of track used is known as Low Vibration Track (LVT), which is held in place by gravity and friction. Reinforced concrete blocks of support the rails every and are held by thick closed-cell polymer foam pads placed at the bottom of rubber boots. The latter separates the blocks' mass movements from the concrete. The track provides extra overhead clearance for larger trains. UIC60 (60kg/m) rails of 900A grade rest on rail pads, which fit the RN/Sonneville bolted dual leaf-springs. The rails, LVT-blocks and their boots with pads were assembled outside the tunnel, in a fully automated process developed by the LVT inventor, Roger Sonneville. About 334,000 Sonneville blocks were made on the Sangatte site. Maintenance activities are less than projected. The rails had initially been ground on a yearly basis or after approximately 100MGT of traffic. Maintenance is facilitated by the existence of two tunnel junctions or crossover facilities, allowing for two-way operation in each of the six tunnel segments, and providing safe access for maintenance of one isolated tunnel segment at a time. The two crossovers are the largest artificial undersea caverns ever built, at long, high and wide. The English crossover is from
Shakespeare Cliff, and the French crossover is from Sangatte.
Ventilation, cooling and drainage The ventilation system maintains greater air pressure in the service tunnel than in the rail tunnels, so that in the event of a fire, smoke does not enter the service tunnel from the rail tunnels. There is a normal ventilating system and a supplementary system. Twin fans are mounted in vertical shafts where digging for the tunnel began, on both sides of the channel: two in
Sangatte, France, and two more at
Shakespeare Cliff, UK. The normal ventilating system is connected direct to the service tunnel and provides fresh air through the cross- passages into the running tunnels, where it is dispersed by the piston effect of the train and shuttle movements. Only one fan on each side is ever running, the second being available as a backup. The supplementary ventilating system is a separate emergency system and can be used to control smoke or supply emergency air within the tunnels. On both systems, the fans are normally run on supply mode, pulling in air from the outside, but they can also be used in extraction mode to remove smoke or fumes from the tunnels. Two cooling water pipes in each rail tunnel circulate chilled water to remove heat generated by the rail traffic. Pumping stations remove water in the tunnels from rain, seepage, and so on. During the design stage of the tunnel, engineers found that its aerodynamic properties and the heat generated by high-speed trains as they passed through it would raise the temperature inside the tunnel to . As well as making the trains "unbearably warm" for passengers, this also presented a risk of equipment failure and track distortion. Due to R22's
ozone depletion potential and high
global warming potential, its use is being phased out in developed countries. Since 1 January 2015, it has been illegal in Europe to use HCFCs to service air-conditioning equipment; broken equipment that used HCFCs must be replaced with equipment that does not use it. In 2016,
Trane was selected to provide replacement chillers for the tunnel's cooling network. The York chillers were decommissioned and four "next generation" Trane Series E CenTraVac large-capacity (2,600kW to 14,000kW) chillers were installed—two in Sangatte, France, and two at Shakespeare Cliff, UK. The energy-efficient chillers, using
Honeywell's non-flammable, ultra-low GWP
R1233zd(E) refrigerant, maintain temperatures at , and in their first year of operation generated savings of 4.8
GWh—approximately 33%, equating to €500,000 ($585,000)—for tunnel operator
Getlink.
Rolling stock Rolling stock used previously == Operators ==