Beil Segmental Lining

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
1
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27. September,
June 17,2004
2008
Design Principles and Inputs

Construction Systems
Segment Lining Systems
Ring Geometry
Sealing Systems
Requirements to Systems
Influences
Joint Configurations
Bolts / Centering Tools
Tolerances
D2
Content of this presentation
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Andreas Beil
Concrete Segments for Tunnel Linings Field of Application and Design
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2008
D2
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)
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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
D2
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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D2
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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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
D2
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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D2
Single lining system with invert segment
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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
D2
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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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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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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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
Dtwyler solution
D2
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
D2
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
D2
Centering tools and fastening elements
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BOLTEDLINING
D2
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
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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U
DI
RA
+-1mm
mm
+3
RA
DI
+-2
US
TH
IC
KN
ES
S
+1m
m
CIRCUMFERENTIAL LENGTH +-1mm
D2
Tolerances
m
m
SEGMENT PARTITION +-0.02
44
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GO
DIA
NA
m
-1m
+
D
OR
C
L
T
WID
m
-1m
+
H
WID
TH
+-1m
Tolerances
LENGTH +-1mm
45
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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
Basically universal ring and left-right-systems
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June 17,2004
2008
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System requirements related to application

and utilization
Segment systems for road tunnels
Single- and double-lining systems
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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Thank you
for your
attention!
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June 17,2004
2008

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D2

Prague, June 17, 2008

Design Principles and Inputs

Content of this presentation

Principles of Segmental Linings

Approx. Length of tunnel with fixed diameter

Combine TBM- and segment designer immediately

Basic Inputs for Design of Segmental

Dual requirements of TBM and lining (e.g. width of the

Master ring for checking of defined tolerance and segment details

Segment Lining system with fixed diameter

Construction Systems (1)

Lining totally with segments

Construction Systems (2)

Expendet segment Lining with variable diameter

Construction Systems (3)

Lining Systems with invert segments

Lining system with conventional supporting

Construction Systems (4)

precast segments in invert only

Single lining system with invert segment

Construction Systems (5)

Double-lining systems with segments and final

Construction Systems (6)

Sustainable final lining constructed as cast-in-place inner

Construction Systems (7)

Double-lining systems with segments and

Double Lining System

Construction Systems (8)

Double-lining system with invert segments

Example for Trapezoid Segments

Rhomboid key stone segment

Example for Hexagonal Segments

Details of Segment Geometry

Parallel Ring system

Ring Geometry Examples

Metro & Railway

Big Diameters and offsets

Watertightening Capacity of Gaskets

Interaction Thrust Pressure

Example of Longitudinal Joint

Example of Longitudinal Joint

Example of Joint including Gasket

Flat partial area joints

Joint formations - Shapings

Circumferential Flat Joint

Longitudinal Joint (Groove-Tongue)

Centering Tools and Fastening Elements

Centering tools and fastening elements

Shear capacity test curves of dowels

Example for dowel hole in radial joint

CIRCUMFERENTIAL LENGTH +-1mm

SEGMENT PARTITION +-0.02

System requirements related to application

Segment system for Metro tunnels

System requirements related to application

Segment system for water galleries and tunnels

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