Recommendations for the design, production and installation of segmental rings

Recommendations for the design, production and installation of segmental rings DAUB Deutscher Ausschuss für unterirdisches Bauen e. V. German Tunnelling Committee (ITA-AITES) DAUB Recommendations for the design, production and installation of segmental rings (10.2013) page 2 of 46 Recommendations for the design, production and installation of segmental rings Publisher: Deutscher Ausschuss für unterirdisches Bauen e. V. (DAUB) German Tunnelling Committee (ITA-AITES) Mathias-Brüggen-Str. 41, 50827 Cologne / Germany Tel. +49 - 221 - 5 97 95-0 Fax +49 - 221- 5 97 95-50 E-mail: info@daub-ita.de www.daub-ita.de Published by the DAUB (German Tunnelling Committee) working group "Lining Segment Design" Members of the Working Group Dr.-Ing. Bodo Billig, Hochtief Consult, Essen Dipl.-Ing. Thomas Böhme, Wayss+Freytag Ingenieurbau AG, Frankfurt Dipl.-Ing. Peter Diete, Bilfinger Construction GmbH, NL Tunnelbau, München Prof. Dipl.-Ing. Fritz Grübl, PSP Consulting Engineers GmbH, München, und Hochschule für Technik, Stuttgart (chairman) Prof. Dr.-Ing. Frank Heimbecher, ehem. BAST, Bergisch-Gladbach, jetzt Hochschule für Technik, Münster (corresponding member) Prof. Dr.-Ing. Dieter Kirschke, Beratender Ingenieur, Ettlingen Dr.-Ing. Roland Leucker, STUVA Köln (corresponding member) Dr.-Ing. Ulrich Maidl, MaidlTunnelconsultants GmbH & Co. KG (corresponding member) Prof. Dr.-Ing. Peter Mark, Ruhr-Universität Bochum Dr.-Ing. Peter-Michael Mayer, Züblin AG, Stuttgart (deputy chairman) Dipl.-Ing. Matthias Neuenschwander, Lombardi Engineering Ltd., Minusio (TI) Dipl.-Ing. Walter Neumaier, Ing. Büro Spiekermann, Duisburg (corresponding member) Dipl.-Ing. Franz-Hubertus Beck, Ing. Büro Vössing (corresponding member) Dipl.-Ing. Winfried Schuck, Deutsche Bahn AG TBT, München Dr.-Ing. Ernst-Rainer Tirpitz, Bilfinger Construction GmbH, Wiesbaden Dr.-Ing. Dieter Winselmann, Ing.-Büro Prof. Duddeck und Partner GmbH, Braunschweig Corresponding Employee of the Working group Dipl.-Ing. (HTL) Johann Lemmerer, ÖBB Infrastruktur AG, Wien Dipl.-Ing. Lars Babendererde, Babendererde Engineers GmbH, Bad Schwartau, Animateur ITA Working-group 14, Mechanized Tunnelling Dr.-Ing. Benno Ring, MaidlTunnelconsultants GmbH & Co. KG Dipl.-Ing. Thomas Putke, Ruhr-Universität Bochum DAUB Recommendations for the design, production and installation of segmental rings (10.2013) page 3 of 46 Abstract........................................................................................5 1 General............................................................................6 1.1 Purpose of the recommendations...............................6 1.2 Scope of application. .....................................................6 1.3 Definitions.......................................................................6 1.4 Abbreviations. .................................................................7 2 Overview of typical lining segment systems............................................................................8 3 Segment design...........................................................10 3.1 Description of the one-pass precast segmental ring..............................................................10 3.1.1 General aspects of tunnel lining. ...............................10 3.1.2 Ring geometry. ..............................................................10 3.1.3 Design of the segmental ring.....................................11 3.1.4 Principle of ring building.............................................11 3.2 Joint design. ..................................................................11 3.2.1 Joint types.....................................................................11 3.2.2 Joint shapes. .................................................................12 3.2.3 Connections..................................................................12 3.3 Mountings in the segmental ring. ..............................13 3.4 Manufacturing tolerances. .........................................13 3.4.1 Fundamental considerations. .....................................13 3.4.2 Measurements for the determination of tolerance compliance.................................................15 3.4.3 Tolerance requirements..............................................15 3.4.4 Exceeding the manufacturing tolerances. ...............15 3.5 Notes for the design....................................................17 3.5.1 Concrete cover.............................................................17 3.5.2 Reinforcing spacing. ....................................................17 3.5.3 Minimum reinforcement.............................................17 4 Sealing of the segment joints. ...................................18 4.1 Fundamentals...............................................................18 4.2 Choice of the sealing profile......................................18 4.3 Mode of action of the segment seal.........................18 4.4 Typical tests of sealing profiles.................................19 4.5 Bolting............................................................................19 4.6 Concrete spalling adjacent to the sealing groove............................................................................19 4.7 Dimensional and weight tolerances of the sealing profile...............................................................20 4.8 Long-term behavior of the sealing profile. ...............20 4.9 Frame corners..............................................................20 4.10 Water tightness requirements...................................20 5 Structural planning.....................................................22 5.1 Subsoil oil properties (geology, hydrology).............22 5.2 Influence of the annular gap filling on the calculations. ..................................................................23 5.3 Action and action combinations – Dimensioning concept..........................................................................23 5.3.1 Permanent actions:. .....................................................23 5.3.2 Regularly occurring variable actions.......................23 5.3.3 Rarely occurring actions............................................23 5.3.4 Accidental actions.......................................................23 5.3.5 General notes on verifications of load-bearing capacity.................................................24 5.3.6 Serviceability verifications.........................................25 5.4 Determination of internal forces – Calculation method...........................................................................25 5.4.1 Truss model...................................................................26 5.4.2 Continuum calculation................................................28 5.5 Determination of the internal forces and stresses from the construction process..................29 5.5.1 Split tensile load resulting from jacking forces.............................................................................29 5.5.2 Slab stress due to misalignment or exceeded tolerances in the ring joint.......................29 5.5.3 Stress from transport, storage and installation processes.................................................29 5.5.4 Splitting tensile from the restoring force of the seal groove........................................................30 5.6 Individual verifications of the segment joints...............................................................................30 5.6.1 Permissible concrete compressive stress at partial surface pressure.........................................30 5.6.2 Verification of connections........................................33 5.6.3 Verification of the longitudinal joint on the key segment...........................................................33 5.7 Peculiarities in the use of steel fibers......................33 5.7.1 General..........................................................................33 5.7.2 Mode of action of the fibers.......................................34 5.7.3 Experience with steel fiber reinforced concrete segments......................................................35 5.7.4 Basis of calculation.....................................................35 5.7.5 Determining properties of the concrete in tests. ...........................................................................35 5.7.6 Calculation notes.........................................................36 6 Structural fire protection. ...........................................37 6.1 Introduction. ..................................................................37 6.2 Actions...........................................................................37 6.3 Ways of ensuring structural fire protection............37 6.4 Fire protective claddings and fire tests. ...................37 6.4.1 Fire protection plasters...............................................37 6.4.2 Fire protection panels.................................................37 CONTENTS DAUB Recommendations for the design, production and installation of segmental rings (10.2013) page 4 of 46 6.4.3 Concrete with high fire resistance. ...........................37 6.4.4 Conclusion. ....................................................................38 6.5 Mathematical studies. .................................................38 7 Durability. ......................................................................39 7.1 Requirements. ...............................................................39 7.2 Aging mechanisms......................................................39 7.3 Recommendations to improve durability.................39 7.4 Peculiarities in the use of steel fibers......................40 8 Peculiarities of two-pass lining...............................41 9 Special designs (crosscuts, steel segments, transition to open construction)...............................42 9.1 Crosscuts. ......................................................................42 9.1.1 Introduction. ..................................................................42 9.1.2 Placement of the crosscut opening..........................42 9.1.3 Support of the segments. ............................................42 9.1.4 Steel segment frames.................................................42 9.1.5 Bolting or dowelling in the ring joints.......................43 9.1.6 Steel structures............................................................44 9.1.7 In situ concrete frames...............................................44 9.1.8 Creating the crosscut opening..................................44 9.1.9 Seal connections.........................................................45 9.1.10 Safety seals. ..................................................................45 9.2 Steel segments.............................................................45 9.2.1 Introduction. ..................................................................45 9.2.2 Formation. ......................................................................45 9.2.3 Production.....................................................................45 9.2.4 Installation. ....................................................................46 9.3 Transition to open methods of construction (stations, portals).........................................................46 9.3.1 Introduction. ..................................................................46 9.3.2 Replaceable seal constructions................................46 9.3.3 Permanent seal constructions. ..................................47 10 Sets of rules, standards and publications..............48 10.1 Sets of rules and standards.......................................48 10.2 Publications..................................................................49 Appendix....................................................................................50 A.1 Notes on the production of segments in a precast plant. ................................................................50 A.2 Segment production....................................................50 Stationary production – Steps...................................50 Carousel production – steps deviating from stationary production..................................................50 Curing.............................................................................50 Interim storage / Maturing storage. ..........................50 Concrete repair............................................................50 Open air storage. ..........................................................50 Materials.......................................................................50 Quality assurance / testing. ........................................51 Occupational Safety....................................................51 A.3 Tunnelling. .....................................................................51 DAUB Recommendations for the design, production and installation of segmental rings (10.2013) page 5 of 46 Abstract The recommendations give an overview of the state of the art for the design, the production and the assembly of the tunnel lining made of precast segmental rings. They were executed by the working group “Segmental Ring Design” of DAUB (German Tunnelling Committee). The recom- mendations give a résumé of the construction fundamentals and the necessary calculations and verifications for the di- mensioning of the precast segments according to the actual standards. Moreover they give references for the design of transverse constructions to cross passages and portal build- ings. Also treated are the dimensioning for fire loads and the use of steel fibres. DAUB Recommendations for the design, production and installation of segmental rings (10.2013) page 6 of 46 1 General 1.1 Purpose of the recommendations The recommendations for the design, production and in- stallation of segmental rings were prepared by the German Tunnelling Committee (DAUB) working group „Lining Segment Design“. They are intended to reflect the state of the art in the field of tunnel linings using precast concrete components and comprise a basis for the design and cal- culation of the segment rings with regard to serviceability properties, construction and quality assurance. The findings and experience from design practice already available and regulations already published, such as Guide- line 853 of the DB AG [1], the ZTV-ING Part 5, Section 3 [3] and the corresponding Austrian guideline [48], Con- crete Lining Segment Systems, are summarized below and presented in relation to one another. Recommendations are thus provided for the production of qualitatively high grade tunnel linings to ensure their usability over a service life of about 100 years with low maintenance costs. 1.2 Scope of application The recommendations can be applied for the manufacture of linings made of precast reinforced concrete or steel fiber reinforced concrete parts (reinforced concrete or steel fiber reinforced concrete segments) in traffic tunnelling, for wa- ter tunnels (headrace tunnels for hydroelectric power sta- tions, drinking water tunnels, waste water tunnels) as well as in infrastructure tunnelling. They deal mainly with one- pass segmental lining, where particularly high demands are placed on the individual segment and on the ring system. They can, however, also be applied mutatis mutandis for lining segment systems without sealing and two-pass lining as well as for shaft construction with segmental lining. 1.3 Definitions To prevent conceptual (mis)interpretations, the key techni- cal terms used are summarized and explained below. Sealing system Sealing system consisting of sealing strips (sealing frames) that enclose each individual segment and in the interaction of all the segments as a shell ensure per- manent sealing of the tunnel tube against groundwater. One-pass lining All static and structural requirements of the tunnel lining are handled by the segmental ring. No further internal concrete shell is installed that contributes to load bearing or sealing. The annular gap grouting mortar and any fire protection linings on the inner side of the lin- ing segment, if they have no static or sealing function, do not count as an additional shell. Tapering („conicity“) of the segmental ring Difference be- tween the maximum and minimum ring width (dimension of the ring in the longitudinal direction of the tunnel). Longitudinal joint Periphery and contact area between the lining segments within a ring. The longitudinal joints run approximately parallel to the tunnel axis. Mechanized tunnelling Tunnelling using a tunnel boring machine (TBM), where uploads/Industriel/ tunnel-guide.pdf

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