MECHANIZED EXCAVATION OF LONG TRANSPORT TUNNELS Concrete Segments for Tunnel Linings Field of Application and Design Prague, June 17, 2008 / Alfred Schulter D2 Consult ZT-GmbH, Linz / Austria 1D2 Seite 1 27. September, June 17, 2004 2008
Content of this presentation Design Principles and Inputs Construction Systems Segment Lining Systems Ring Geometry Sealing Systems Requirements to Systems Influences Joint Configurations Bolts / Centering Tools Tolerances 2D2 2 Seite 2 27. September, June 17, 2004 2008
Principles of Segmental Linings Approx. Length of tunnel with fixed diameter exceeding approx. 2,000 meter. 3D2 Combine TBM- and segment designer immediately after fixing of method and before start of design work. Both designs should show minimum 10 years of relevant experience. Client to specify dual requirements of TBM and lining. Distribution of technical responsibilities at interface. 3 Seite 3 27. September, June 17, 2004 2008
Basic Inputs for Design of Segmental Linings Minimum Radius of Tunnel allignment Maximum Diameter of Tunnel 4D2 Dual requirements of TBM and lining (e.g. width of the ring, segments per ring, max. loadings of TBM thrusts) Geotechnical datas (e.g. max. overburden, max. ground water pressure) Other requirements (e.g. fire loadings, tunnel operation loadings, earth quake, minimum tolerances) 4 Seite 4 27. September, June 17, 2004 2008
Thrusters of TBM 5D2 5 Seite 5 27. September, June 17, 2004 2008
Master Ring Master ring for checking of defined tolerance and segment details 6D2 6 Seite 6 27. September, June 17, 2004 2008
Construction Systems (1) Segment Lining system with fixed diameter Lining totally with segments Closed longitudinal joints fixed outer diameter Filling of annular space with gap grouting material 7D2 7 Seite 7 27. September, June 17, 2004 2008
Construction Systems (2) Expendet segment Lining with variable diameter Lining totally with segments Variable outer diameter Segment system with compressing elements Filling of annular space with gap grouting material 8D2 8 Seite 8 27. September, June 17, 2004 2008
Construction Systems (3) Lining Systems with invert segments Integration of purpose formed invert segments Function: immediate fastening (invert, carriageway, drainage) Invert segment part of final lining 9D2 9 Seite 9 27. September, June 17, 2004 2008
Construction Systems (4) Lining system with conventional supporting elements and integrated invert segments precast segments in invert only Use of shotcrete, anchors and cast-in-place concrete Carriageway with drainage Part of final segment lining 10D2 10 Seite 10 27. September, June 17, 2004 2008
Single lining system with invert segment 11D2 11 Seite 11 27. September, June 17, 2004 2008
Construction Systems (5) Single-lining with segments Full support of excavation survace Structural safety of tunnel Serviceablity of tunnel (water tightness, durability) Quality requirements to tunnel lining surface 12D2 12 Seite 12 27. September, June 17, 2004 2008
Construction Systems (6) Double-lining systems with segments and final lining of cast in place concrete Sustainable final lining constructed as cast-in-place inner layer Absorbing of ground water loadings by final cast-in-place lining Segment lining will absorb all other geotechnical loadings 13D2 13 Seite 13 27. September, June 17, 2004 2008
Construction Systems (7) Double-lining systems with segments and functional final lining Function of final lining is limited (e.g. fire loading, sealing, collision protection, ) Function or segment lining equal to single-lining system 14D2 14 Seite 14 27. September, June 17, 2004 2008
Double Lining System 15D2 15 Seite 15 27. September, June 17, 2004 2008
Construction Systems (8) Double-lining system with invert segments Combination of invert segment with shotcrete final lining Function of integrated invert segment Immediate fastening Protection of excavation intrados Serviceability of tunnel construction (water tightness, durability) 16D2 16 Seite 16 27. September, June 17, 2004 2008
Segment Systems Rectangle system Trapezoid system Rhomboid system Hexagonal system 17D2 17 Seite 17 27. September, June 17, 2004 2008
Example for Trapezoid Segments 18D2 18 Seite 18 27. September, June 17, 2004 2008
Rhomboid key stone segment 19D2 19 Seite 19 27. September, June 17, 2004 2008
Example for Hexagonal Segments 20D2 20 Seite 20 27. September, June 17, 2004 2008
Details of Segment Geometry 21D2 21 Seite 21 27. September, June 17, 2004 2008
Ring Geometry Parallel Ring system Parallel Ring system with corrections rings Left-Right-Systems Universal Ring Systems 22D2 22 Seite 22 27. September, June 17, 2004 2008
Watertightness Membrane Systems Installation between segment lining and cast-in-place concrete final lining Absorbing of ground water loadings by cast-in-place concrete final lining Gaskets Installation in special grooves of the segment joints Absorbing of full ground water loadings by the segments 23D2 23 Seite 23 27. September, June 17, 2004 2008
Ring Geometry Examples 24D2 24 Seite 24 27. September, June 17, 2004 2008
Tailor-Made Gaskets Tunnel-Type Challenge Dätwyler solution Metro & Railway Tunnels Mountain Basis Tunnels Road Tunnels Water Supply Tunnels Combined Sewer Overflow Tunnels Low to Medium Water Pressure Low Reaction Forces Tunnel Ovalization with gap opening Steps of Waterpressure Very High Water Pressure Big Diameters and offsets Hydrocarbons, Fuels High Pressure Potable Water Contact Big Diameters, Waste Water Contact Soft Geometry, Soft Corner, Sliding Surface Specially Stable Geometry, Hydro-swelling top and lips Wide Profile, Protected surface or CR Rubber Stable Geometry, Drinkwater Rubber Quality Hydro-swelling on top, EPDM Rubber 25D2 25 Seite 25 27. September, June 17, 2004 2008
Gasket Details 26D2 26 Seite 26 27. September, June 17, 2004 2008
Watertightening Capacity of Gaskets 27D2 27 Seite 27 27. September, June 17, 2004 2008
Interaction Thrust Pressure Gasket Relaxation STAGE1 STAGE2 0 28D2 28 Seite 28 27. September, June 17, 2004 2008
Example of Longitudinal Joint 29D2 29 Seite 29 27. September, June 17, 2004 2008
Example of Longitudinal Joint with Guiding Rod 30D2 30 Seite 30 27. September, June 17, 2004 2008
Example of Joint including Gasket 31D2 31 Seite 31 27. September, June 17, 2004 2008
Joint formations - Shapings Flat partial area joints Groove-Tongue joints Conkave-Convex joints 32D2 32 Seite 32 27. September, June 17, 2004 2008
Circumferential Flat Joint 33D2 33 Seite 33 27. September, June 17, 2004 2008
Longitudinal Joint (Groove-Tongue) 34D2 34 Seite 34 27. September, June 17, 2004 2008
Centering Tools and Fastening Elements Purpose Connection of joints (temporary / permanent) through boltings and dowels For guaranting stability during implementation For prohibiting movements Allow a more precise and simple installation of segments 35D2 35 Seite 35 27. September, June 17, 2004 2008
Inclined Bolt 36D2 36 Seite 36 27. September, June 17, 2004 2008
Centering tools and fastening elements Methods Flexible tools Guiding rod (longitudinal joint), dowel (ring joint) Dowells Bolts In longitudinal joints for absorption of traction and thrust No additional bolting necessary For temporary protection during assembling In longitudinal and ring joints Mostly inclined or curved 37D2 37 Seite 37 27. September, June 17, 2004 2008
Joints BOLTEDLINING CONEX LINING 38D2 38 Seite 38 27. September, June 17, 2004 2008
Dowels 39D2 39 Seite 39 27. September, June 17, 2004 2008
Shear capacity test curves of dowels Force [kn] 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 Dowel CONEX capacity: 102,0 kn max. def.: 15,6 mm 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Deformation [mm] Dowel CONEX Dowel SOF-CLIP Dowel ANEX BUCLOCK (Heavy Duty) Dowel ANEX capacity: 97,0 kn max. def.: 15,0 mm BUCLOCK (Standard) Dowel BUCLOCK Heavy Duty capacity: 100,0 kn max. def.: 20,0 mm Dowel SOF-CLIP capacity: 97,6 kn max. def.: 23,0 mm Dowel BUCLOCK (Standard) capacity: 60,0 kn max. def.: 20,0 mm 40D2 40 Seite 40 27. September, June 17, 2004 2008
Steel Dowel 41D2 41 Seite 41 27. September, June 17, 2004 2008
Example for dowel hole in radial joint 42D2 42 Seite 42 27. September, June 17, 2004 2008
Segment Tolerances 43D2 43 Seite 43 27. September, June 17, 2004 2008
Tolerances THICKNESS +-3mm CIRCUMFERENTIAL LENGTH +-1mm RADIUS +-2mm +-1mm SEGMENT PARTITION +-0.02 RADIUS +-1mm 44D2 44 Seite 44 27. September, June 17, 2004 2008
Tolerances WIDTH +-1mm WIDTH +-1mm DIAGONAL CORD +-1mm LENGTH +-1mm 45D2 45 Seite 45 27. September, June 17, 2004 2008
System requirements related to application and utilization Segment systems for railway tunnels Single- and double-lining systems All systems except hexagonal system in use Segment system for Metro tunnels Mostly single-lining sealed system All systems except hexagonal system in use Basically universal ring and left-right-systems 46D2 46 Seite 46 27. September, June 17, 2004 2008
System requirements related to application and utilization Segment systems for road tunnels Single- and double-lining systems All systems except hexagonal system in use Regarding sealing function all feasible Segment system for water galleries and tunnels Mostly single-lining systems with open segment layer Closure of joints ex post Mostly parallel ring systems (with correction segments) and hexagonal segments in use 47D2 47 Seite 47 27. September, June 17, 2004 2008
48D2 Thank you for your attention! 48 Seite 48 27. September, June 17, 2004 2008