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MECHANIZED EXCAVATION OF LONG TRANSPORT TUNNELS
Concrete Segments for Tunnel Linings –Field of Application and Design
Prague, June 17, 2008Andreas Beil / Alfred Schulter
D2 Consult ZT-GmbH, Linz / Austria
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Content of this presentation
Design Principles and InputsConstruction SystemsSegment Lining SystemsRing GeometrySealing SystemsRequirements to SystemsInfluencesJoint ConfigurationsBolts / Centering ToolsTolerances
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
• Approx. Length of tunnel with fixed diameterexceeding approx. 2,000 meter.
• Combine TBM- and segment designer immediatelyafter 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 interfa ce.
Principles of Segmental Linings
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June 17, 2008
• Minimum Radius of Tunnel allignment
• Maximum Diameter of Tunnel
• Dual requirements of TBM and lining (e.g. width of thering, segments per ring, max. loadings of TBM thrusts )
• Geotechnical datas (e.g. max. overburden, max. ground water pressure)
Basic Inputs for Design of Segmental Linings
• Other requirements (e.g. fire loadings, tunneloperation loadings, earth quake, minimum tolerances)
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Thrusters of TBM
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Master Ring
Master ring for checking of defined tolerance and segme nt details
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 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
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 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
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 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
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Construction Systems (4)
Lining system with conventional supportingelements 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
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Single lining system with invert segment
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 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
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 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-placelining
Segment lining will absorb all other geotechnical loadings
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 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
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Double Lining System
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Construction Systems (8)
Double-lining system with invert segmentsCombination of invert segment with shotcrete final liningFunction of integrated invert segment
Immediate fasteningProtection of excavation intradosServiceability of tunnel construction (watertightness, durability)
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Segment Systems
Rectangle system
Trapezoid system
Rhomboid system
Hexagonal system
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Example for Trapezoid Segments
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Rhomboid key stone segment
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Example for Hexagonal Segments
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June 17, 2008
Details of Segment Geometry
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Ring Geometry
Parallel Ring system
Parallel Ring system with corrections rings
Left-Right-Systems
Universal Ring Systems
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Watertightness
Membrane SystemsInstallation between segment lining and cast-in-placeconcrete final liningAbsorbing of ground water loadings by cast-in-placeconcrete final lining
GasketsInstallation in special grooves of the segment jointsAbsorbing of full ground water loadings by thesegments
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June 17, 2008
Ring Geometry Examples
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Tailor-Made Gaskets
Tunnel-Type Challenge Dätwyler solution
Big Diameters and offsetsHydrocarbons, Fuels
High PressurePotable Water Contact
Big Diameters,Waste Water Contact
Tunnel Ovalizationwith gap opening
Steps of WaterpressureVery High Water Pressure
Soft Geometry, Soft Corner,
Sliding Surface
Specially StableGeometry,
Hydro-swellingtop and lips
Wide Profile, Protected surface or
CR Rubber
Stable Geometry, Drinkwater Rubber
Quality
Hydro-swellingon top,
EPDM Rubber
Road Tunnels
Metro & RailwayTunnels
Water SupplyTunnels
Low to Medium Water Pressure
Low Reaction Forces
Combined SewerOverflowTunnels
Mountain BasisTunnels
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June 17, 2008
Gasket Details
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June 17, 2008
Watertightening Capacity of Gaskets
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June 17, 2008
Interaction Thrust PressureGasket Relaxation
STAGE 2
0
STAGE 1
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Example of Longitudinal Joint
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Example of Longitudinal Jointwith Guiding Rod
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Example of Joint including Gasket
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Joint formations - Shapings
Flat partial area joints
Groove-Tongue joints
Conkave-Convex joints
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Circumferential Flat Joint
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Longitudinal Joint (Groove-Tongue)
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Centering Tools and Fastening Elements
Purpose
Connection of joints (temporary / permanent) throughboltings and dowels
For guaranting stability during implementation
For prohibiting movements
Allow a more precise and simple installation of segments
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June 17, 2008
Inclined Bolt
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Centering tools and fastening elements
MethodsFlexible tools
Guiding rod (longitudinal joint), dowel (ring joint)Dowells
In longitudinal joints for absorption of traction and thrustNo additional bolting necessary
BoltsFor temporary protection during assemblingIn longitudinal and ring jointsMostly inclined or curved
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June 17, 2008
CONEX LINING
BOLTED LINING
Joints
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June 17, 2008
Dowels
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June 17, 2008
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Deformation [mm]
For
ce [k
N]
Dowel CONEX Dowel SOF-CLIP Dowel ANEXBUCLOCK (Heavy Duty) BUCLOCK (Standard)
Dowel ANEXcapacity: 97,0 kNmax. def.: 15,0 mm
Dowel CONEXcapacity: 102,0 kNmax. def.: 15,6 mm
Dowel SOF-CLIPcapacity: 97,6 kNmax. def.: 23,0 mm
Dowel BUCLOCK(Standard)capacity: 60,0 kNmax. def.: 20,0 mm
Dowel BUCLOCKHeavy Dutycapacity: 100,0 kNmax. def.: 20,0 mm
Shear capacity test curves of dowels
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June 17, 2008
Steel Dowel
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Example for dowel hole in radial joint
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June 17, 2008
Segment Tolerances
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June 17, 2008
Tolerances
SEGMENT PARTITION +-0.02°
THICKNESS +-3mm
RAD
IUS +-2m
mR
ADIU
S +-
1mm
+-1mm
CIRCUMFERENTIAL LENGTH +-1mm
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
Tolerances
LENGTH +-1mm
DIAGONAL CORD +-1mm
WID
TH
+-1
mm
WID
TH
+-1
mm
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Andreas BeilConcrete Segments for Tunnel Linings – Field of Applicat ion and Design
June 17, 2008
System requirements related to applicationand utilization
Segment systems for railway tunnelsSingle- and double-lining systemsAll systems except „hexagonal system“ in use
Segment system for Metro tunnelsMostly single-lining sealed systemAll systems except „hexagonal system“ in useBasically universal ring and left-right-systems
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June 17, 2008
System requirements related to applicationand utilization
Segment systems for road tunnelsSingle- and double-lining systemsAll systems except „hexagonal system“ in useRegarding sealing function all feasible
Segment system for water galleries and tunnelsMostly single-lining systems with open segment layerClosure of joints ex postMostly parallel ring systems (with correction segments) and hexagonal segments in use
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June 17, 2008
Thank youfor your
attention!