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MECHANIZED EXCAVATION OF LONG TRANSPORT TUNNELS Concrete Segments for Tunnel Linings – Field of Application and Design
Prague, June 17, 2008 Andreas Beil / Alfred Schulter D2 Consult ZT-GmbH, Linz / Austria 1
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Design Principles and Inputs Construction Systems Segment Lining Systems Ring Geometry Sealing Systems Requirements to Systems Influences Joint Configurations Bolts / Centering Tools Tolerances
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Content of this presentation
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Principles of Segmental Linings
• Approx. Length of tunnel with fixed diameter exceeding approx. 2,000 meter.
• 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. 33 Andreas Beil Concrete Segments for Tunnel Linings – Field of Application and Design Seite 3
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Basic Inputs for Design of Segmental Linings • Minimum Radius of Tunnel allignment • Maximum Diameter of Tunnel
• 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)
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Thrusters of TBM
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Master Ring
Master ring for checking of defined tolerance and segment details
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Segment Lining system with fixed diameter
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Construction Systems (1)
Lining totally with segments Closed longitudinal joints – fixed outer diameter Filling of annular space with gap grouting material
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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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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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Lining system with conventional supporting elements and integrated invert segments
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Construction Systems (4)
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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Single lining system with invert segment
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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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Double-lining systems with segments and final lining of cast in place concrete
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Construction Systems (6)
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
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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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Double Lining System
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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)
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Segment Systems
Rectangle system Trapezoid system Rhomboid system Hexagonal system 17 17 Andreas Beil Concrete Segments for Tunnel Linings – Field of Application and Design Seite 17
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Example for Trapezoid Segments
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Rhomboid key stone segment
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Example for Hexagonal Segments
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Details of Segment Geometry
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Ring Geometry
Parallel Ring system Parallel Ring system with corrections rings Left-Right-Systems Universal Ring Systems
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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
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Ring Geometry Examples
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Tunnel-Type
Challenge
Metro & Railway Tunnels
Low to Medium Water Pressure Low Reaction Forces
Soft Geometry, Soft Corner, Sliding Surface
Mountain Basis Tunnels
Tunnel Ovalization with gap opening Steps of Waterpressure Very High Water Pressure
Specially Stable Geometry, Hydro-swelling top and lips
Road Tunnels
Big Diameters and offsets Hydrocarbons, Fuels
Wide Profile, Protected surface or CR Rubber
Water Supply Tunnels
High Pressure Potable Water Contact
Stable Geometry, Drinkwater Rubber Quality
Combined Sewer Overflow Tunnels
Big Diameters, Waste Water Contact
Hydro-swelling on top, EPDM Rubber
Dätwyler solution
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Tailor-Made Gaskets
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Gasket Details
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Watertightening Capacity of Gaskets
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Interaction Thrust Pressure Gasket Relaxation STAGE1
STAGE2
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Example of Longitudinal Joint
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Example of Longitudinal Joint with Guiding Rod
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Example of Joint including Gasket
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Flat partial area joints
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Joint formations - Shapings
Groove-Tongue joints Conkave-Convex joints
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Circumferential Flat Joint
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Longitudinal Joint (Groove-Tongue)
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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
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Inclined Bolt
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Methods Flexible tools Guiding rod (longitudinal joint), dowel (ring joint) Dowells In longitudinal joints for absorption of traction and thrust No additional bolting necessary Bolts For temporary protection during assembling In longitudinal and ring joints Mostly inclined or curved
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Centering tools and fastening elements
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BOLTEDLINING
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Joints
CONEXLINING
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Dowels
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Shear capacity test curves of dowels 140
Dowel BUCLOCK Heavy Duty capacity: 100,0 kN max. def.: 20,0 mm
Dowel CONEX capacity: 102,0 kN max. def.: 15,6 mm
130 120
Dowel ANEX capacity: 97,0 kN max. def.: 15,0 mm
110 100
Force [kN]
90 80
Dowel SOF-CLIP capacity: 97,6 kN max. def.: 23,0 mm
70 60 50 40 30
Dowel BUCLOCK (Standard) capacity: 60,0 kN max. def.: 20,0 mm
20 10 0 0
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Deformation [mm] Dowel CONEX BUCLOCK (Heavy Duty)
Dowel SOF-CLIP BUCLOCK (Standard)
Dowel ANEX
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Steel Dowel
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Example for dowel hole in radial joint
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Segment Tolerances
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U DI RA
+-1mm
mm
+3
RA DI
+-2
US
S
TH IC KN ES S
+1m m
CIRCUMFERENTIAL LENGTH +-1mm
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Tolerances
m m
SEGMENT PARTITION +-0.02°
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NA
m -1m + D OR C L
T WID
m -1m + H
WID TH
+-1m
m
Tolerances
LENGTH +-1mm
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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
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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
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D2 Thank you for your attention!
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