ASSOCIATION FRANAISE DES TUNNELS

ET DE LESPACE SOUTERRAIN

Organization member of the AFTES

www.aftes.asso.fr

AFTES
Recommendations

Watertightness of precast
concrete lining segments

GT9R6A1

WATERTIGHTNESS OF PRECAST CONCRETE LINING
SEGMENTS
AFTES welcomes comments on this article before final approval
Version 1 1998 - Approved by Technical Committee 7 April 1998
ES
MERCIER (SOFRETU), and MEYNIEL (RATP)
PREAMBLE
AFTES Working Group 9 on tunnel water-
tightness has previously drafted and published
Guidelines on the watertightness of precast
segmental concrete tunnel linings.
They dealt with gaskets and other points
directly concerned with them.
FT
Since tunnel watertightness does not depend
solely on the gaskets used in this type of
construction, it was found necessary to com-
mit to writing fur ther ideas on the other
causes potentially affecting water tightness
performance and propose recommended
leakage preventive methods.
1. Materials Excessive porosity
Concrete deterioration
A
2. Segment Non-homogeneous mix
casting (honeycombs, segrega-
tion)
TUNNELS ET OUVRAGES SOUTERRAINS HORS-SERIE N 1 2005
AFTES WORKING GROUP 9
GUIDELINES ON
Drafted by
LONGCHAMP (Bouygues),
TYPES OF DISTRESS LIABLE The causes addressed arise from:
TO AFFECT WATERTIGHT- 1. Constituent material of segments
2. Segment casting
NESS 3.Transport and storage of segments
(excluding gaskets) 4. Segment installation
- Mass porosity 5. Loads due to shield thrust
- Cracking due to temporary or permanent 6. Grouting of annular space between lining
and tunnel bore
loads
7. Llining ring and segment performance
- Concrete shrinkage cracking (insignificant in
during tunnel operation.
precast lining segments)
This list clearly illustrates that, at each stage of
- Flaws or distress affecting the gasket groove
or gasket contact surface. the life of the lining, events may adversely
affect tunnel watertightness.
ANALYSIS OF CAUSES OF DIS-
TRESS LIABLE TO AFFECT WATER- For clarity, details of the analysis of the causes
TIGHTNESS OF SEGMENTAL and possible remedies are presented in tabu-
LININGS lar form.
Insufficient concrete density Special laboratory tests on concrete formulation
Gap graded aggregate with porosity checks
Cement and admixture proportions Identification and analysis of natural and artificial
(contamination) factors in surrounding ground
Physical/chemical reaction with liable to detract from concrete durability
environment inside or outside tunnel Second lining and watertight system
Protection applied to lining extrados (coal tar)
Hydraulic binder quality Test cement and concrete for compatibility with
environment
Compatibility between binder Cement selection
and aggregate
All causes connected with concrete Compatibility of reinforcement design with
casting, especially insufficient concrete composition (bar spacing ver sus
VIBRATION aggregate size)
Check vibration intensity
Experiments on effects of vibration and influence
zone and efficiency
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 Watertightness of precast concrete lining segments
Bubbles (at gasket
position)
Poor segment geometry
ES
Spalls, chipped arrises,
cracking
Spalls, chipped arrises,
FT
cracking
Poor gasket bonding
A
Inadequate protection to
hydrophilic gaskets
3. Segment trans- Spalls, chipped arrises,
port and storage cracking
TUNNELS ET OUVRAGES SOUTERRAINS HORS-SERIE N 1 2005
Rough machined mould surfaces
Form release agents
Mould manufacturing tolerances
Mould not rigid enough, deforms
Inadequate kinematics of moving
demoulding parts
'Thermal shock' especially when
demoulding (Dt between concrete
and outside temperature)
Effects of segment handling systems
(gripping and turning)
Concrete sticking to mould
Inadequate concrete early strength
Flaws in reinforcement; tolerance on
cage assembly
Positioning of cages in mould
Inadequate concrete/adhesive/gasket
complex
Poor workmanship
Adhesive out of date
Gaskets expanded before fitting
Impact damage (accidental or when
positioning)
247
For large items, resilient mould mounting that
does not dampen vibration
Avoid leaky moulds
Specify mould roughness
Specify finished mould manufacturing tolerances
as segment design volume, not just as tolerances
on lengths and flatness
See Fascicule 56A
Special attention to tolerances on angles of bea-
ring surfaces between segments and between
rings
Include effects of vibration in mould design
Demoulding kinematics to be addressed in
segment mould design to specify draft angles
Analyse segment stresses with reference to
handling equipment effectively used
Consider suction stresses due to demoulding.
Protect segments by inser ting compressible
material under gripper jaws
Specify mould roughness
Choice of release agent and/or mould lining
Avoid sharp edges
Test effective strength on demoulding
Specify tolerances on concrete cover on
drawings
Position reinforcement cages with accurate tem-
plates specially designed for each segment type
Specific testing and inspection
Support reinforcement cages
Write detailed procedure for adhesive prepara-
tion and application and gasket fitting
Use-by date to be shown on packaging
Use within stated time
Storage conditions to be stated and met
Proper protection from the weather
Write detailed procedure for each handling and
storage operation
Use compressible supports on storage, transport
and handling equipment
 Watertightness of precast concrete lining segments

Supports poorly positioned or adjus- Provide suitable supports during storage

ted (especially with newly-cast seg- Handling machines to have inching mechanism or
ments) proportional speed control
Attention to storage support material, positio-
ning and levelling, and base
Stock management to avoid excessive handling

Stacks too high Provide enough storage yard area

4. Segment installa- Spalls, chipped arrises, See sections 2 & 3

tion cracking Segment installation kinematics Plan movements of segment in its immediate
environment when homing into place
Detailed study of key, counterkey and machine

ES
interfaces when designing lining ring

Broken arrises on key and Insufficient reinforcement Allow for stray stresses often associated with
counterkey introduction of key between counterkeys

Excessively tight ring Check free space between counterkeys before

inserting key
Accurate control of segment installation from
first to last

Gasket damaged by rub- Excessive friction Grease longitudinal gaskets before installing seg-
bing or snagging Poor bond ment
Check gasket bond

Key dislodges when Key self-guiding system not working Provide for guidance between key and counter-
nearly home keys in segment design
FT
5. Loads applied by Chipped arrises, cracking, Thrust cylinder pads poorly seated Use resilient thrust pads
shield broken edges, misalign- Check kinematics of cylinder movement in tigh-
ment test curves

5.1.Thrust Poor transmission of thrust loads bet- Analyse stress paths in successive rings
ween lining segments Keep segment casting tolerances as tight as pos-
sible
Arrange for loads to be 'filtered' between rings

Rear effects of thrust cylinders in tight Mount cylinders on resilient ring or similar device
curves to allow enough angular movement between
cylinders and shield

Excessive thrust load from cylinders Control pressure to groups of cylinders rather
than on/off control
A

Excessive pressure from thrust cylin- Check bearing area

der pads Check pad stiffness
Check segment tightness near pad positions and
contacts between rings

5.2. Shield rubbing Chipped arrises, cracking Clearance between lining and tailskin Specify clearance with sketch
against lining rings too tight Use tailskin with free articulation

Lining ring off-centre Procedure for setting out rotational position of

ring
High performance guidance/navigation system

Shield guidance In the event of errors, specify correction curve

compatible with design,TBM and pinching of ring

TUNNELS ET OUVRAGES SOUTERRAINS HORS-SERIE N 1 2005

248
 Watertightness of precast concrete lining segments

6. Grouting stresses Distress at contact sur- Excessive grouting pressure Provide active and passive overpressure devices
faces between segments on grout pumps

Out-of-round Imbalance between grouting holes Provide balanced grouting device

Dislodged key segment Grout mix suitability study

Upward movement of Incomplete grouting Control grouting pressure

lining due to buoyancy Grout formulation unsuitable Malfunctioning grouting plant and equipment

7. Segmental lining Other forms of distress Effects of combined stress due to Review design assumptions
during operation of (unusual) groundwater, soil, and internal and
tunnel external loads

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Ageing Electrical continuity between segments (bon-
ding)
Cathodic protection
Materials quality
Reinforcement completely surrounded by
concrete

Displacements between Various Dowels between rings

segments or between
rings
FT
A

TUNNELS ET OUVRAGES SOUTERRAINS HORS-SERIE N 1 2005

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