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D2

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
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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 22

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Concrete Segments for Tunnel Linings – Field of Application and Design
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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.
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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) 44

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Thrusters of TBM

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Master Ring

Master ring for checking of defined tolerance and segment details 66

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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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Concrete Segments for Tunnel Linings – Field of Application and Design
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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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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

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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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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

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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

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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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Tailor-Made Gaskets

Tunnel-Type Challenge Dätwyler solution


Low to Medium Soft Geometry,
Metro & Railway
Water Pressure Soft Corner,
Tunnels Low Reaction Forces Sliding Surface

Tunnel Ovalization Specially Stable


Mountain Basis with gap opening Geometry,
Tunnels Steps of Waterpressure Hydro-swelling
Very High Water Pressure top and lips

Big Diameters and offsets Wide Profile,


Road Tunnels Hydrocarbons, Fuels Protected surface or
CR Rubber

Water Supply High Pressure Stable Geometry,


Potable Water Contact Drinkwater Rubber
Tunnels
Quality

Combined Sewer Hydro-swelling


Big Diameters,
Overflow on top,
Tunnels
Waste Water Contact
EPDM Rubber 25
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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

0
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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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Joint formations - Shapings

Flat partial area joints

Groove-Tongue joints

Conkave-Convex joints

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Concrete Segments for Tunnel Linings – Field of Application and Design
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Circumferential Flat Joint

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Concrete Segments for Tunnel Linings – Field of Application and Design
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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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Concrete Segments for Tunnel Linings – Field of Application and Design
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Inclined Bolt

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Concrete Segments for Tunnel Linings – Field of Application and Design
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Centering tools and fastening elements

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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Concrete Segments for Tunnel Linings – Field of Application and Design
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Joints
BOLTEDLINING

CONEXLINING

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Concrete Segments for Tunnel Linings – Field of Application and Design
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Dowels

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Shear capacity test curves of dowels
140
Dowel BUCLOCK
Dowel CONEX Heavy Duty
130
capacity: 102,0 kN capacity: 100,0 kN
max. def.: 15,6 mm max. def.: 20,0 mm
120

110 Dowel ANEX


capacity: 97,0 kN
100 max. def.: 15,0 mm

90

80
Force [kN]

70 Dowel SOF-CLIP
capacity: 97,6 kN
60 max. def.: 23,0 mm

50

40

30
Dowel BUCLOCK
20 (Standard)
capacity: 60,0 kN
10 max. def.: 20,0 mm

0
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
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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Concrete Segments for Tunnel Linings – Field of Application and Design
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Tolerances

CIRCUMFERENTIAL LENGTH +-1mm

m
RA

1m
+-1mm
TH DI

+-
IC SU
KN

US
+-2
ES

DI
S
mm

RA
+-
3 m
m
SEGMENT PARTITION +-0.02°

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Concrete Segments for Tunnel Linings – Field of Application and Design
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Tolerances

m
+-1m
TH
WID

m
+-1m
D
COR
L
NA
GO
m

DIA
+-1m
H T
WID

LENGTH +-1mm

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Concrete Segments for Tunnel Linings – Field of Application and Design
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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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Concrete Segments for Tunnel Linings – Field of Application and Design
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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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Concrete Segments for Tunnel Linings – Field of Application and Design
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Thank you
for your
attention!

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Concrete Segments for Tunnel Linings – Field of Application and Design
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